The Beacon For Your Desk - Siemens
Volume 1 January 2014 siemens.com/cnc4youThe Shopfloor MagazineThe beacon foryour deskNew CNC4you lighthouseworkpieceWhy not just start?Semmelrogge: from white goods retailer tohighly flexible contract manufacturerHands-on CNC training atthe Kiel FjordKiel University of Applied Sciences usesstate-of-the-art machine tools
CNC4YOU 1/2014 ContentsCNC technology in northern GermanyHorst Witte GerätebauKG is a market leaderin high-precisionfixturing systemsSiemens AG0704Why not just start?Semmelrogge: from white goods retailer to highlyflexible contract manufacturer07A head start through precisionHorst Witte Gerätebau: high-tech fixturingsystems from the north of Germany10“Nearby instead of Far East”Mürwiker Werkstätten: socially responsible andprofitableTraining12RBZ Kiel usesSinumerik 840D sl andthe simulationsoftware SinuTrain toprovide up-to-date andpractical training12Simulation establishes safetyTraining at RBZ Kiel14Hands-on CNC training at the Kiel FjordKiel University of Applied Sciences uses state-ofthe-art machine toolsSiemens AGOn the shopfloor16The beacon for your deskNew CNC4you lighthouse workpieceTips and tricksThe lighthouse sampleworkpiece makes iteasy to get startedwith CNC turning atBNW LüneburgSiemens AG1617Milling with SinumerikNews18The machine whispererNew training center for Sinumerik19New language packs for SinuTrain and Sinumerik808D on PC / EventsCover photo: Wolfgang Jvargstorff/FotoliaPublisherSiemens AG,Industry Sector, CommunicationsWerner-von-Siemens-Str. 50,D-91052 Erlangen, Germanysiemens.com/industryPublishing houseArticle No.: E20001-A1760-P610-X-7600Publicis Publishing, P.O. Box 32 40,91050 Erlangen, Germanymagazines-industry@publicis.deCirculation: 7,000Editor: Gabi StadlbauerLayout: Nadine Wachter, Kerstin Rosenow 2014 by Siemens AktiengesellschaftMunich and BerlinAll rights reserved.Drive Technologies DivisionCEO Ralf-Michael FrankeCopy Editor: Susanne Wanke,Verena DebnarThis issue was printed on paper madefrom environmentally friendly,chlorine-free bleached pulp.Editorial responsibility in accordancewith the German press lawBernd HeuchemerDTP: Mario Willms Publicis;TV Satzstudio, EmskirchenThe following products are registeredtrademarks of Siemens AG:Print: Wünsch Offset-Druck GmbH,Neumarkt/Opf., GermanyShopMill, ShopTurn, SINUMERIK,SINUMERIK 808D, SINUMERIK 828D,SINUMERIK 840D sl, SinuTrainResponsible for technical contentHans PischultiEditorial committee chairElke PilhöferIf trademarks, trade names, technicalsolutions, etc., are not referred tospecifically, it does not mean that theyare not protected. The information in thisjournal only includes general descriptionsand/or performance characteristics,which do not always apply in the formdescribed in a specific application, orwhich may change as products aredeveloped. The required performancecharacteristics are only binding if theyare expressly agreed at the point ofconclusion of the contract.
Dear readers,Siemens AGEditorial CNC4YOU 1/2014The north is shining bright – this more or less sums up the research for this issue of CNC4you. The people ofnorthern Germany are used to wind and weather and are generally considered to be calm, easygoing, andeven-tempered. Take a closer look, however, and you will see a very lively high-tech region with aerospacecompanies in the metropolitan area of Hamburg, state-of-the-art medical technology in Kiel, a powerfulautomotive industry in the region of Wolfsburg/Hannover, and innovative energy technology companies andsmall contract manufacturers for metal machining across the region.The current issue of CNC4you provides insight into this extremely vibrant area of Germany. We report aboutinnovative education and training at RBZ Kiel, one of 13 Siemens training partners in the northern area. KielUniversity of Applied Sciences also trains future engineers using Sinumerik 840D sl. The university exploits allthe possibilities of modern five-axis machines, from ShopMill/ShopTurn to DIN programming inprogramGuide, using simulation to protect its valuable machines. We also highlight a hidden champion fromthe northern mid tier: Horst Witte Gerätebau, located in the idyllic town of Elbauen, produces highly precisealuminum parts with Sinumerik 828D on a custom-tailored machine tool, for the company‘s much soughtafter clamping systems. Witte is not the only example showing how important capable tool machine dealersare for the industry. With Knuth, the north can boast one of the most successful and innovative machine tooldealers in Germany. We tell the story of a small family-owned machine shop expanding its portfolio with aKnuth machine and Sinumerik 808D.Are you interested in new developments in Sinumerik controls? Don’t miss the opportunity – come visit uson one of the upcoming trade fairs. It will be worth your time. I look forward to seeing you there!Ingo BartschSales Manager CNC / Application Technology3
Small series withhigh-voltage connectors forcurrent transformersSiemens AGSemmelrogge: from white goods retailer to highly flexible contract manufacturerWhy not just start?As a successful small business owner over the age of 60, is it wise to enternew markets? Horst Semmelrogge from Malberg, Germany, will probablynever understand such skeptical questions. He prefers to just do it. So inearly 2013 he invested in a Knuth Numturn 420 with Sinumerik 808D –a combination that could easily catch on.Of course, we don’t find Horst Semmelrogge athis desk in the office. He’s standing in thesmall production facility that he built next tohis house, keeping a fatherly eye on his 14 employees and lending a hand himself to get a machine forwindings running again.Semmelrogge set up his business in 1980, shortlyafter passing his exams to become a master trades-4man in electrical engineering. He started out as a retailer and repairman of white goods.“My father made windings. We designed and builtour own winding machine so that we could make abit of extra income. Then I went around to all the villages and presented our service to local companies,where I stumbled upon more interest than expected,”says Semmelrogge.
CNC technology in northern Germany CNC4YOU 1/2014“ Particularly as a small business,you want good technical supportfrom the manufacturer. When I’mmaking investment decisions,service is an important factor.”Siemens AGHorst Semmelrogge, CEOCoincidence? Real entrepreneurs grabopportunities like thesewith the Sinumerik control, I’ve also invested in anew hydrogen welding robot and a milling machine,”Semmelrogge explains.His youngest employee is standing beside theKnuth machine with him, optimizing programs forthe current workpiece: a high-voltage connector forvoltage transformers in railroad engineering acrosswhich 40,000 V will eventually run.“This is a perfect solution for us. He is being trainedon Sinumerik 840D sl at school. These youngsterssee their future in working with highly efficient CNCcontrols. They are committed to their work, and Ihave the security of always being able to find employees who have mastered the control system of mymachine. It even applies to multiple technologies, asthe Sinumerik CNCs for turning and milling are verysimilar in their operation – a huge plus point,” saysSemmelrogge.And because the boss wants to operate his machines himself when necessary, there has beensomething of a role reversal going on since spring2013. The youngsters are educating the boss on theintricacies of the Sinumerik CNC.In 1989 he started a conversation at a football clubwith someone working for the Ritz company. Ritzproduced current and voltage transformers for therail industry. Semmelrogge arranged an interview atthe company, obtained his first order, and provedhimself. A few years later, when the company waslooking for a partner for the outsourcing of coil production, Semmelrogge resolutely seized the chance.He offered Ritz reliable production to specification,with delivery at very short notice.“At the beginning there were perhaps 10–12 different coils. Now we manufacture more than 100 varying versions; we also produce other intermediateproducts and preassembled cables. We do that almost to order, at a few hours’ notice. Flexibility andreliability are our strengths. We know that production at the customer’s premises runs smoothly onlyif we deliver on time and as needed,” Semmelroggeexplains. The economic advantage for Ritz is that orders for prefabricated coils and other componentsare synchronized at Semmelrogge with the company’s own production, so there is hardly any need to Technical support desiredkeep these intermediate products in stock. As a result, Semmelrogge and his team are valued partners Ingo Bartsch, Siemens sales manager for northernwith whom the company has been working for many Germany, reports that this division of roles and thenew training methods are becoming increasinglyyears.widespread in small businesses: “The workload inIntroduction to machiningthese companies continues to increase, and youngemployees in small businesses are being sent lessFrom coil windings to machining – but why? “My often to comprehensive face-to-face trainingnephew is joining the company. I’d like to hand him courses at the manufacturer’s premises due to timea future-proof, state-of-the-art company and to get and cost pressures.” Siemens’ answer to this is modit onto a broader footing. Apart from that, I’ve al- ular Sinumerik training courses with shorter face-toways remained curious and I can see opportunities face times; video tutorials on the Internet; webin machining for new business with new and exist- based training courses; and the SinuTrain software,ing customers. In addition to the Knuth Numturn 420 which mirrors the Sinumerik CNC exactly on a PC.5
CNC4YOU 1/2014 CNC technology in northern GermanyTechnology in DetailSinumerik 808D for standard turning andmilling machines User-friendly technology versions DIN/ISO high-level language programming compatiblewith Sinumerik 828D and Sinumerik 840D slSiemens AG Wide variety of technology cycles Convenient tool management Advanced Surface for perfect milling results Task-oriented onboard tutorials for fast implementationThe first of its kind in Germany:Knuth Numturn 420 with Sinumerik 808D Manual Machine Plus for CNC operation similar to aconventional turning machineValuable add-ons Free “ 8 08D on PC” software for training and offline- programming Free videos and tutorials Standard 36-month warranty on materials and on-sitesupportHelp for self-help – employees from the Internet andmobile phone generation are familiar with thesesystems from their training and from their privatelives and thus find them easy to use.Semmelrogge has remained curious and openminded, even though he’s a little over 60, and healso finds these new ways of learning both good andpractical. Nevertheless, he wouldn’t like to go without visits like this one today from Bartsch: “Particularly as a small business, you want good technicalsupport from the manufacturer. When I’m making investment decisions, service is an important factor.Visits always help me and my employees get a bit further: tips about programming, tools, and maintenance; explanations about new functions and technologies; industry buzz; and lots more.”“And for me there’s coffee and rolls,” Bartsch sayswith a grin, and then adds more seriously: “As themanufacturer’s employees, we also get a lot out ofthese visits. The closer we get to the workpieces andactual work with the machine, the better.”New opportunities with Sinumerik 808DWhen choosing his machine, Semmelrogge went tothe Knuth headquarters in Wasbek, Germany, and heis still enthusiastic about the machines on display6and the advice he was given. “Of course a five-axismachine would be great, but based on my experience as an entrepreneur, I always invest according toneeds. A machine like that must first earn a lot ofmoney on my shopfloor before I move up to the nextstage. The solution recommended by Knuth was perfect for me,” the businessman explains.This solution, however, was anything but standard,as Bartsch from Siemens explains: “Sinumerik 808Dwas not designed for the Central European market.Agents like Knuth drew our attention to the fact thatthey also experience strong demand from smallcompanies for simple, sometimes semimanual shopfloor machines. These customers are looking for acost-effective solution but with a future-proof control system. It should adapt flexibly to investmentsat a later date and offer a consistent CNC platformfrom turning and milling to multitasking, from thesemimanual machine to the five-axis machining center. And we can offer all this with the Sinumerikfam ily.”Of course, Semmelrogge with his direct mannerand hands-on attitude had some input here. The firstSinumerik 808D used in Germany is running on hismachine on his shopfloor. Now Siemens and its partner Knuth intend to tailor other packages in response to the wishes of contract manufacturers andmachine shops.Semmelrogge is glad to hear this: “It’s good and ithelps us. I can see that from my machine. It’s nice tosee the big players start off simply too.” Info and contactsiemens.com/cnc4youingo.bartsch@siemens.com
CNC technology in northern Germany CNC4YOU 1/2014Horst Witte Gerätebau: high-tech fixturing systems from the north of GermanyA head startthrough precisionSiemens AG“Hidden champion” is the perfect description for Horst Witte GerätebauBarskamp KG. Even the company building in the small community ofBarskamp on the river Elbe has an unassuming presence, almost hidden inthe countryside. But from a technical point of view, this restraint stops assoon as you walk through the door. High-tech and precision engineeringhave made the company a leading supplier of modular fixturing systemsand a leader in vacuum fixturing technology for the automotive andaerospace industries. A machine with a Sinumerik 828D CNC plays a keyrole in this success.7
CNC4YOU 1/2014 CNC technology in northern GermanyChallenging: extrudedaluminum profilesToday, many other fixturing systemscomplement the original product offering. Starting from its headquarters withvarious production plants in Barskamp,the company expanded with branchesin Singapore, Mexico, the United States,and Brazil. Klinge explains: “The branchoffices are closer to the customers, andour employees advise, design, and a ssemble locally. Production of our s ystems and fixturings, however, isconcentrated entirely at our Barskampsite.” Why is that? “The bars for themodular Alufix system are producedfrom extruded aluminum profiles,which forms the base for their highstrength construction. At the sametime, the stresses arising in the mate-rial place extreme demands on the process chain on the metalworking shopfloor. The expertise required to machine aluminum is our company’s keycompetence and competitive advantage.”Technology in DetailDeep hole drilling inSinumerik OperateSinumerik Operate provides the userwith convenient cycles for deep holedrilling. It offers options for chipbreaking and chip removal. You can findan overview of all definable parametersat siemens.com/cnc4you. The drillingcycles are available both in ShopMill and pro gramGuide.One of a kind: the key machine forface machiningAs we walk through the production f acility with Klinge, he gives us insightinto the various process steps for theAlufix modular system. First, the surfaces of the blank profiles are milled totheir standard lengths, which also resolves the stresses in the extruded section. Then the profile lengths are cut toorder. The profiles, which can be combined in a versatile manner via quickconnector and fixed to base plateslater, are available in profile dimensionsof 16 16 mm, 25 25 mm, 40 40 mm,and 50 50 mm.The machining of the profile head hasa crucial effect on the accuracy that canbe achieved with the subsequent fixture. “The milling machine for face machining is the key player in this process– it has a significant impact on qualityand efficiency in the production section. So we were very cautious when investing in the new machine at the end planned process optimizations. Bothof 2012. We had very specific ideas factors were having a negative impactabout the capabilities and configura- on efficiency.”Eventually, machine tool dealertion required,” Klinge explains. “Wewere increasingly experiencing down- Helmut Diekmann found the solution:times with our previous machine, and “Witte’s process-specific requirementsit was proving difficult to carry out are very specialized, and it was impos-The horizontalmachining of theprofile heads takesplace on a millingmachine (left) withcustom-tailoredadaptationsSiemens AGSiemens AGThis also includes thehydraulic clampingfor various profilesizes (right)8Siemens AGEstablished in 1969 in the idyllicv illage of Barskamp, Horst WitteGerätebau Barskamp KG has rapidly developed into a market leader infixturing systems and vacuum clampingtechnology. Looking back to the company’s beginnings, production managerWilhelm Klinge says: “The breakthroughcame with the development of ourmodular Alufix system. Lightweight butstable, extremely flexible and reusableas a profile kit – and built, of course,with absolute precision – our Alufix systems were an immediate hit with customers in the automotive and aerospace industries and soon became established in the global marketplace too.”
CNC technology in northern Germany CNC4YOU 1/2014sible to achieve them cost-effectivelywith a standard machine. In the end,we opted for a machine fitted throughout with Sinumerik – from the operatorpanel and software to the motors andwiring harness. With the approval ofand in cooperation with the Asian machine manufacturer, we then plannedand carried out the required adjustments to the machine.”Adjustments optimize the processThe rigid machine table was fitted witha clamping fixture adapted to Witte’svarious aluminum profiles so as toachieve the necessary precision inclamping and machining. The cleverpart of this solution is that the doors tothe machine’s machining space wereprovided with a “hatch” – two small additional sliding doors – to permit horizontal machining of longer profiles aswell. So when necessary, it is also possible to machine faces or heads of profiles that protrude well beyond the machining space.The capacity of the machine’s toolchanger was also doubled to accommodate 60 tools. This means that thetypes and sizes of tools required for allthe profile sizes are always ready foruse. “Finally, we installed an extra chipguard because the chips were thrownreally high during dry horizontal machining of the aluminum with rapid traverses, and they could be found all overthe machine, inside and out,” Diekmann remembers.The programs for face machiningwere easily imported into the Sinumerik828D CNC and optimized. “We are inthe business of precision engineering,and we have to work with machiningtolerances that are often already usedup during clamping. This is why we useonly high-end CNCs in all our machines.In face machining in particular, theSinumerik CNC pays off because herewe are machining with tolerances of 10 µm. The machine operators also really like the convenience because theycan quickly and reliably select the frequent program changes that crop up inorder-specific machining,” Klinge explains.After the first face machining, theprofiles are given the holes characteristic of the Alufix modular system in afurther machining step. Then they goback to the machine again for face machining. This is when the second profilehead is milled – completely and precisely according to the holes made previously. This guarantees the precisionof the systems constructed later at thecustomers’ premises. Every minute inaccuracy in the profile head would ultimately build up over the length of theprofiles or as they are interlinked andwould lead to unacceptable deviations.A clear advantage for throughputFor pro
The beacon for your desk New CNC4you lighthouse workpiece Why not just start? Semmelrogge: from white goods retailer to highly flexible contract manufacturer Hands-on CNC training at the Kiel Fjord Kiel University of Applied Sciences uses state-of-the-art machine tools.
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