According to a survey by Siemens Financial Services – an international finance provider with companies such as Siemens Finance & Leasing – there are several factors that help manufacturing companies to operate successfully in an increasingly competitive and difficult environment: with access to state-of-the-art technology and improved cash flow. With more capacity, flexibility and productivity as well as competitive prices.

What is needed for this? Another success factor: A smart alternative to buying a machine. A financing product like PerformanceFinance. With the best of four worlds: the digital world with IoT analytics, the real world with comprehensive services. The financial world with a short contract term and attractive rates. And the world of machining. With top technology from the CHIRON Group.

The digital world – the basis for consistently excellent machine performance
Ensure consistently high performance and avoid unplanned downtimes: To this end, the machining center selected for PerformanceFinance is monitored cyclically over the entire term of the contract. Vibration data from relevant components is collected and automatically compared with the data from commissioning according to the target/actual principle. The IoT data shows the machine condition, wear can be detected at an early stage and proactively rectified in the real world through remote support or on site.

The real world – for sustainably productive operation and value retention
Reactive and preventive services combined into a comprehensive, intelligent maintenance solution: CHIRON Group Service is responsible for this part of PerformanceFinance. The services at a glance:

• Event monitoring for proactive management of warnings and events

• Remote diagnostics and remote maintenance for higher machine availability

• Proactive maintenance for optimum machine condition based on IoT analysis

• Dynamic maintenance based on checklist with replacement of wear parts

• Main spindle service with fast replacement and repair

• Troubleshooting with flat rate for technicians and spare parts

The service package not only ensures long-term productive operation, it also preserves the value of the machining center. This has a positive effect on financing.

The world of finance – for planning security with attractive rates
Thanks to IoT analytics and intelligent maintenance, the production center is always in top condition. The residual value can therefore be set higher compared to conventional financing, and the repayment amount correspondingly lower. The installments for maintenance and financing costs remain constant over the entire term of 36 or 48 months. In addition, the combination of full service and condition monitoring ensures a longer machine life cycle and therefore greater sustainability.

The world of machining – for example with the next generation of the 15 Series
In order to cover the widest possible range of applications, all machine variants of the 15 Series are integrated into PerformanceFinance in addition to the FZ 16 S five axis and the preconfigured FZ 15 S five axis baseline and FZ 15 W baseline machining centers. Especially all variants of the next generation. With one spindle, with two spindles, for 5-axis simultaneous machining, with basket or chain-type tool changer, with workpiece changing during machine operation. Plus optimized features such as new rotary tables from the CHIRON Group and the Siemens SINUMERIK ONE control system.

The best of four worlds – in an individual, intelligent combination
Financing with PerformanceFinance starts with working out the right machine configuration. Spindle and table variant, number of tool positions, choice of HSK-A interface, coolant system, chip conveyor, tool breakage monitoring, measuring probe, clamping logic, the PowerSave energy-saving module and other features: The CHIRON Group experts work together with the customer to define all of this along the requirements matrix.

Once the configuration is complete, the framework data for use is defined: For example, 48 months running time with 4,000 operating hours per year. All key data is incorporated into an individual complete offer. If everything fits, Siemens Finance & Leasing makes the production center available for the defined period.

Financing examples

What happens after the end of the term? There are three options at that point: Return of the machining center, purchase or follow-up financing via PerformanceFinance.

Want to find out more about PerformanceFinance?
Julia Pfaender, Finance Project Manager at the CHIRON Group, would love to hear from you.

The BTU Center for Hybrid Electric Systems Cottbus (chesco) conducts research into climate-friendly mobility of the future with a focus on aerospace. It develops, tests and optimizes new, sophisticated materials and component geometries, going through a large number of development and design loops. It produces prototypes and pre-series using a combination of different processes – including 3D printing, laser cutting, punching and, as a rule, milling.

At the Hammerwerk Fridingen, on the other hand, they work on parts production for forging tools and series production with high cutting performance of components for engines and chassis. For the mobility of today, for customers from Automotive, Non-Automotive and Off-Highway.

The applications could not be more different. And yet both customers opted for the FZ 19 S five axis, the first machining center in the new 19 Series, even before it was launched on the market.

Senior Product Manager Markus Vollmer says this shows that »Our development strategy was exactly right. We wanted a machine with universal application possibilities. Flexible, of course. But that's what everyone is counting on. We have equipped the FZ 19 S five axis with the necessary power to precisely machine materials such as Inconel or titanium. And with the corresponding milling performance and dynamics to also manufacture series highly productively on a single-spindle machine in a compact space.«

Another key advantage of the FZ 19 S five axis: With 700 mm travel in Z, the working area is designed to be ideal for 5-axis simultaneous machining of workpieces with a cubic capacity of up to 580 mm or cylinders up to 820 mm in diameter and 700 mm in length. The first machine variant of the new series is also available with an HSK-A100 interface and a maximum spindle torque of 408 Nm for machining components from blanks, for example for aerospace applications.

As with all CHIRON Group machining centers, the modular design allows individual configuration exactly according to requirements. For example, with motor spindles developed and manufactured in-house, various rotary table packages and tool magazines in three sizes each for the HSK-A63 and HSK-A100 interface, with capacity for 36 to 196 tools.

The highlights at a glance

• Precise, flexible and high-performance production

• Machining a wide range of materials, from aluminum to titanium alloys

• Up to 196 tools for highly complex workpieces and parts manufacture involving a wide range of variants

• Low thermal expansion of the machine thanks to actively cooled components

• High dynamic and static rigidity – the machine bed has a mobile gantry design

• Gantry rotary axes with torque direct drive, without backlash from gearbox

• Tool set-up during operation for maximum output

• Easy access for set-up, automation and crane loading

• Established, high-performance control technology: Siemens SINUMERIK ONE or Fanuc 31iB5

• Intuitive operation via TouchLine for safe user guidance

In addition, the 19 Series is prepared for the integration of all SmartLine digital systems – keywords: advance simulation and optimization of machining operations, condition monitoring, preventive machine protection. »At BTU chesco, for example, the software systems are used to prepare the experimental processes for industrial use,« explains Till Oeschger, Project Manager at the CHIRON Group. The open platform Industrial Edge from Siemens can also be integrated.

Would you like to know more about the new FZ 19 S five axis or the FZ 19 S mill turn variant, which can also be used to productively implement turning applications for large and heavy workpieces? Get first-hand information at AMB 2024, Hall 10, Stand A51.

You can find out more about the new series here.

In a recent article in the trade magazine MaschinenMarkt, various factors were named that speak in favor of automating manufacturing processes: On the one hand, there is a lack of manpower throughout Europe. Companies can hardly find workers for simple, manual tasks and certainly not for shift work. On the other hand, product and variant diversity is increasing and quantities are falling. Production must therefore be able to manufacture even small batches economically in rapid succession. What's more: Many customers do without warehousing and want their parts and components »just in time« or »just in sequence«. Delivery times are shortening and must be able to be planned precisely.

No questions left unanswered – with automation solutions from the CHIRON Group
Internal CHIRON Group statistics confirm this development: Five years ago, one in three project machines was automated, today it is seven out of ten. Thomas Marquardt, Head of Automation, names two key questions that he hears more and more often from customers: »Will I still find operators for simple tasks, for second and third shift work, in two, five or ten years' time? And: How can I increase productivity and realize unit cost benefits at the same time?«

Thomas Marquardt's answer to both questions: »In terms of production technology and economics, process automation simply has the greatest potential to save time, optimize unit costs and deploy skilled workers elsewhere for more demanding tasks. We can also see this in our statistics. If automation is used, modules for additional tasks should also be integrated in many cases.«

For the CHIRON Group, the answer to the growing demands is an equally growing portfolio for more autonomy in production – both for new machining centers and existing machines. Starting with integrated automation, for example for workpiece handling on the 715 Series models, and continuing with units for the smallest machine, the Micro5, where the Feed5 handling system takes over the loading and unloading of up to two machining centers. The new DTS (driverless transport system) can also be used to automatically feed and remove workpiece stacks with raw and finished parts.

Standardized or individual? Both!
Standard automation with a Variocell UNO is available in three versions: The smallest version has a footprint of just 1.5 square meters and can be combined with the 08 and 12 Series and can hold 24 pallets weighing up to 10 kg.

The M variant is designed for productive combination with 08, 12 and 15 Series machining centers, now with extended storage capacity for 30 pallets and a total load capacity of 350 kg for even greater autonomy. Parts handling is fully automated, with optional retooling of workpiece gripper jaws and fixture clamping jaws.

The largest Variocell UNO is available in two basic versions: with base frame on the left for the 15 and 18 Series, and the double-spindle machine DZ 16 W, and with base frame on the right for the 16, 19 and 22 Series. The separation of the workpieces provided in layers or as bulk material can be carried out robot-supported with camera recognition by means of bin picking.

In addition to the handling robot and workpiece store, each Variocell UNO automation unit can have additional components added to it: Multiple grippers, turning stations, blow-off stations, simple cleaning, labeling and vision systems are just a few examples from the modular system.

Do you need a complex solution with a high degree of autonomy into which peripheral units will be integrated? A Variocell SYSTEM is designed by the CHIRON Group application exactly as specified in the requirements matrix. Starting with handling systems, gantry or articulated arm loaders, workpiece storage systems for unfinished and finished parts, pallet storage systems, infeed and outfeed systems. And further with a variety of modules for seamless integration: from A for arm loaders to D for deburring to I for inspection systems to W for workpiece storage systems.

In addition, it is possible to automate not only the manufacturing process on a machining center, but also a complex production line – from the provision of the blank to machining, the integration of upstream and downstream processes and end-of-line testing.

Variocell MOVE: Automation is easier and more flexible than ever
The new Variocell MOVE is an automation unit that forms a productive unit with a machining center from the 12, 15, 16, 18, MILL and baseline Series. So far, a typical CHIRON Group unit. But it has one special feature: The unit does not have to be permanent. The compact robot cell with inclined pallet system for intelligent workpiece handling can be combined with alternating milling and mill-turning centers. And provides more autonomy and efficiency exactly where it is needed – for months, weeks or just days.

To ensure that the Variocell MOVE can also show its strengths in short applications, configuration is user-guided and based on predefined matrices via the control panel. They range from the selection of the machining center to clamping devices and gripper configuration to the data of the raw and finished parts and the pick-up and deposit positions on the pallet. Additional functions such as blowing off the device or the finished workpiece are also integrated and easy to select.

Another special feature: In order to keep the unit as compact and mobile as possible while still ensuring maximum safety for the operating personnel, laser scanners form graduated safety zones. If a person approaches, the robot's speed is reduced as a first step. If someone enters the critical area, the system is shut down.

Would you like to know more about how autonomous manufacturing increases productivity and counteracts the shortage of skilled workers? For the CHIRON Group, automation is one of the main themes of their stand at AMB 2024. 

Detailed information on the products – from Feed5 to highly individualized solutions (Variocell SYSTEM) can be found on the Corporate website.

The term »multi-tasking« is commonly used for machines that integrate different processing methods. Why not also for the 715 Series? For Matthias Efinger, Head of Machine Development, this is exactly what makes the difference: »Multi-tasking usually means that different requirements are managed – but this is often at the expense of productivity and efficiency. This is not an option for us nor for our customers! The aim of the further development was to qualify the MT 715 for new, demanding tasks which, in addition to high productivity, require greater flexibility and autonomy.«

Extended machining of shaft parts
Whether milling spindles and transmission shafts in mechanical engineering or rotor shafts for e-mobility: With the new features for the MT 715, components up to 100 mm in diameter and 1,400 mm in length can now be machined from the bar in a continuous process. The working area is extended to a width of 1,550 mm for this purpose.

Instead of a turret with eight positions, the second machining unit of the MT 715 two and MT 715 two⁺ models can also be equipped with a turret for up to twelve tools. This provides more options for additional machining across all applications. A steady rest can be added to the turret for the production of shaft parts. This stabilizes longer shafts with a large diameter or shorter, delicate ones in the process and ensures stable machining conditions at all times, resulting in high-precision results.

Workpiece changing can now also be integrated and automated for large components weighing up to 65 kg. An easy-to-operate, linear handling system picks up the shaft part from above after machining and moves it to the workpiece storage area. The system can also be used for inserting saw cuts and semi-finished products into the working area.

More flexibility, more autonomy for all machining operations
The integrated tool store is now available in three variants: As before with a maximum of 64 or 128 tools with a length of up to 250 mm and – keyword »extended« – now with capacity for 176 tools with a length of up to 450 mm.

Milling, turning and gear cutting – a perfect match!
Nowadays, mill-turn technology, the combination of milling, turning and drilling, is a firmly established factor for batch size 1 and in series production. Why now integrate the gear cutting process into 6-sided complete machining with the MT 715? Michael Wurster, Senior Product Manager: »The market is showing a growing interest in these processes with their wide range of possible applications. Requirements such as smaller batch sizes, high workpiece quality and short call-off times can only be met with even more flexible and productive manufacturing processes. Parts tourism, i.e. outsourcing gear cutting tasks to contract manufacturers, is often no longer the best solution today. If all machining tasks are carried out on one machine in one clamping position instead, the result is much more precise, streamlines production processes and reduces logistics costs.«

Naturally, production according to the Taylor principle produces the highest yield. And for all those who manufacture mass for the automotive, mechanical engineering or other industries, a machine explicitly designed for gear cutting with special kinematics and elaborately designed tools is the best choice. For all those who are confronted with the issue of increasing variance – whether prototype or series manufacturers – the MT 715 offers a reliable alternative for machining parts completely and now also with sophisticated, precise gear cutting.

Complex technologies – easy to parameterize
Gear hobbing, gear skiving, gear broaching, impact gear milling: Depending on the required output, component geometry and machining task , these technologies can be integrated into the MT 715 machine variants. Either as a single option or in combination.

Gear hobbing, for example, is the most productive option for shafts with splines or running gears. However, the component geometry must allow for certain entry and exit paths in order to avoid cuts in part shoulders, for example. If this method is not sufficient, gear skiving is the technology of choice not only for the interior but also for the exterior. If the run-out is also too low for gear skiving, the right technology is available in the form of gear broaching. Do you additionally want to produce face gears or secondary operations such as pointing, backtaper milling and deburring of gears? The CHIRON Group also offers an option for this with impact gear milling.

To enable user-friendly process application, the gear cutting cycles are parameterized directly on the control panel of the machining center. Input is made via context-sensitive masks with intuitive user guidance and plausibility checks.