Technology Days – manufacturing for the future

High precision, automation, and digital technology – this is what the future of metalworking looks like. During the Technology Days event in Chemnitz, Starrag showcased crucial building blocks and highlighted machine developments such as the Heckert H100 compact machining centre.

A sneak preview of the new large machine series that made its premiere was displayed alongside perfectly coordinated peripherals. The event also offered visitors a glimpse of the newly designed production hall, where precision-critical components for a wide range of StarragTornos Group machines are manufactured in a highly automated process with µm accuracy.

“The name ‘Technology Days’ sums up our event perfectly,” emphasised Martin Buyle, CEO of the StarragTornos Group, when welcoming the guests. “Because over the next two days you will have the chance to see technology at its finest.”

Over 200 participants recently filled the ‘reception hall’ at the Starrag Technology Days in Chemnitz, including representatives from around 100 customers across eight different countries. The machining specialists in Chemnitz selected four main topics to present their optimised manufacturing processes, working closely with peripheral suppliers Blum Novotest, FANUC, Fastems, Gefertec, Haimer, HandlingTech, Pimpel, and Siemens.

Maximum productivity per square metre

The first topic, ‘Small dimensions – big impact’, focused on the brand new Heckert H100 4-axis machining centre, which rounds off the top end of the current Heckert compact series. It was demonstrated with a pilot application developed for the Czech vehicle manufacturer Tatra Trucks, in which entire V8 and V12 engines are machined in five operations. Starrag application technologist Rico Ullrich explains: “Using a compact machine for such large parts saves a lot of money – in terms of machine investment, transport, foundations and installation space, right through to the machining process itself. Moreover, we also supplied the process design and developed the four required devices – all in close collaboration with the customer.”

The second topic, the symbiosis of metal 3D printing and 5-axis finish machining, holds great potential for the future. This was presented in the form of a Gefertec arc80X and a Heckert X50 with turning function. “A highlight of our Technology Days,” emphasises Kai Bohle, Director of Sales T&I at the Chemnitz site. “In complex components, the generative process often saves more than 70% of raw material. This reduces the amount of finishing work required, meaning more parts of better quality can be machined in the same time than with conventional methods. It’s still a niche at the moment, but that will change.”

Making good things even better

For the third topic ‘Innovation meets tradition’, Starrag presented a large, unclad machine – the sneak preview of the completely new generation of large machines, which will supersede the successful Heckert Large series in the future. The user can adopt fixtures and NC programmes from previous models as the tried-and-tested kinematics have been retained. Apart from this, the new series has many advantages to offer, as the Product Manager Carsten Bergmann explains: “We have completely redesigned all frame components – beds, columns, and further optimised the machine, particularly with regard to thermal symmetry and chip disposal. We have also managed to reduce the footprint by around 20%.” Even more rigid structural components and ball screws also allow higher cutting values to be realised, which contributes to reduced machining times.

The new large machines are designed as a modular system with four predefined sizes, two of which will be launched in 2025 and the other two through 2026 and 2027. A new module has already been presented on the basic machine, a matrix magazine with space for up to 828 tools.

Starrag machines manufacture Starrag machines

The fourth topic was self-made precision. “Our goal is to manufacture all precision-critical parts ourselves,” explains Kai Bohle. “That’s why we are massively expanding production here at this site.” Central to this are three Heckert HEC 800 X5 with turning function, which feature the Heckert High-Precision Package in addition to the optional extended travel paths. They manufacture pallets and faceplates for B-axes and rotary-drive units, bearing blocks, gearbox housings and much more – fully automated in small and medium series. One important automation element is a Fastems linear storage system with 64 pallet spaces and two set-up stations.

However, the Technology Days focussed less on the Heckert HEC 800 machines manufactured in Chemnitz and more on the actual machining processes. Using the example of pallet machining, Starrag technologist Jan Wilske explained why precision is so important and what requirements must be met on the machine side. Using measurement logs, he impressively demonstrated that tolerances in the single-digit µm range are maintained across all batch sizes – in terms of the evenness, squareness, straightness of the contact surfaces and positions.

A huge concrete foundation could be seen right next to the Heckert HEC 800 machining centres. With an area of 22 by 14m, it provides the framework for the basic structure of a 12m Droop+Rein FOGS HD40 130 R50C high gantry machining centre. With this huge high-speed machining centre from the Starrag site in Bielefeld, the Chemnitz-based company will in future machine all columns, machine beds and other precision-critical large parts for Heckert machines and other brands of the StarragTornos Group to an accuracy of just a few µm.

Digitalisation permeates every level

In order to achieve not only precision but also the desired high productivity, it takes more than outstanding machines and peripherals. It is equally important that companies are well positioned in terms of digitalisation. Starrag is fully aware of this. Accordingly, MDE and PDA systems were introduced in Chemnitz and Rorschacherberg and a detailed planning system was put into operation that supplies every workstation with daily data for optimised work processes – not only in production, but also in design, technology and project management.

At the Technology Days, the themes of automation and digitalisation permeated all four of the event’s main topics. Starrag itself has a lot to offer in this regard, including digital services such as the online fingerprint and new HMI functions for web applications and camera integration. In addition, the British company TTL, which belongs to the StarragTornos Group, presented its Virtual Machine (VM). This can ensure maximum process reliability in the Siemens NX world, even for demanding 5-axis machining operations.

However, process optimisation and simulation using VM solutions and the digital twin were also recurrent themes at the partner booths. The companies presented innovations from the fields of process-integrated measurement technology and robot automation. They explained the latest functionalities in CNC control systems and highlighted the benefits of an end-to-end digitalisation solution for tool clamping and presetting.