cnc4you

Practical knowledge
for the shopfloor

2/2016

siemens.com/cnc4you
CNC 4you 2/2016

Digitalization CNC knowledge

Digitalization: Perfect surface finishes
hype or opportunity? 08 Higher data quality in NC programs
03 Small companies are ready with Top Surface
for the digital change
Complex tasks? No problem
Digitalization from the 09 High-level programming language
perspective of job shops with Sinumerik provides support for special tasks
04 The latest Sinumerik solutions
Perfect — and cost-effective —
profile processing
12 Slotting on CNC turning machines
without special components

The cutting edge of productivity

14 Polygon turning in series production of flats

On the shopfloor
Mold making for racing
16 KME Renntechnik uses innovative Sinumerik
technology for precise parts production

Industry news
Happy birthday, IndustryArena!
Siemens AG

19 The largest online skills network

4 in the industry celebrates its 15th birthday
Success on the racetrack — with
know-how and Sinumerik 840D sl
Retrofit in XXL
26 R&D Steuerungstechnik specializes
in the retrofit of heavy machine tools

Education and training

Finding the best in class
22 The qualifiers for Worldskills 2017 in Abu Dhabi

News

27 Tips and tricks / Production planning

with Sinutrain / Dates

Cover photo: Siemens AG

2
 CNC 4you 2/2016

Digitalization:
hype or opportunity?

Digitalization
Digitalization is the hot topic in every company — or so people think. The
­ uremberg-based market research center GfK and the management consultancy
N
company etventure surveyed managers from 2,000 large German companies
(with revenues greater than €250 million) about the state of digital transfor­mation
in their companies. The results are very different from the image depicted
by company representatives who talk enthusiastically about Industrie 4.0 and
­digitalization on TV and in the press.

Specifically, 65% of those surveyed consider “the defense of existing structures”

to be the biggest obstacle, 42% believe their own company is “too set in its ways”
and 40% believe “management shies away from radical decisions.” In other words,
many large companies are themselves getting in the way of their own digitali­zation
and process innovations — despite the fact that they also expect great b ­ enefits
from digitalization.

The picture is very different for small companies. They are better prepared for
digital change thanks to flatter hierarchical structures and a greater proximity to
customers. What does this mean for CNC contract manufacturers? If new tech­
nologies are implemented in a targeted manner, businesses with the courage to
embrace change will very quickly recognize the opportunities digitalization brings.

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45
 CNC 4you 2/2016

Perfect surface finishes

CNC knowledge

Top Surface creates even surfaces regardless

of the CAM output data quality.

The Advanced Surface intelligent path for the subsequent Sinumerik path
control in Sinumerik MDynamics has control, which results in improved
been extended: Top Surface ensures compensation for inexact data.
the highest surface quality in mold
and die production. This function opti- siemens.com/cnc4you
mizes the data from the CAM system [email protected]

Best Stable milling Improved Perfect

surface quality machines accuracy usability
• Elimination of irregulari- • Significantly quieter “Smoothing” function • Simple graphical
ties from CAD/CAM data machine operation • ON: best surface quality ­operating screens
•  Identical smoothing of • Reduced wear • OFF: smallest structures •  Optimum surface ­quality,
the milling paths inde- • Increased long-term even with s­ tandard
pendent of direction availability ­settings (for most NC
programs)

with Top Surface with Top Surface Smoothing OFF

All pictures: Siemens AG

8
 Siemens AG/Publicis Pixelpark

No problem
Complex tasks?
CNC 4you

9
2/2016

CNC knowledge
CNC 4you 2/2016

CNC programmers increasingly face special tasks that take

them to the limits of classic (DIN 66025) and graphical
CNC programming. CNC high-level programming language
with Sinumerik provides valuable support in this area.

Special tasks in CNC programming ibility of CNC machining programs, sequence of the program is modeled
are common. Whether it be configu- allowing CNC programmers to imple- and checked; then it is optimized “in
rable CNC programs for component ment challenging CNC applications. theory” in an abstract, easy-to-follow
families that differ only in a few geo- format.
metric sizes, certain components that Typical properties of high-level
require their own technology cycle programming languages Not until the last step does the pro-
because not all special tasks can be A key prerequisite for programming grammer translate the flow diagrams
handled using standard cycles or a using high-level languages is com- into concrete commands. The com-
simple operator message to be gener- mands that are readable (“mnemonic”) mands of high-level languages facili-
ated from an ongoing CNC program for the programmer, such as REPEAT, tate extremely efficient translation of
that cannot be fully implemented WHILE, CASE, etc. In addition, the pro- flow diagrams.
using the instruction set offered by grammer defines which variables are
DIN 66025 or graphical CNC program- used in the program and which vari- More flexibility as a standard
ming (e.g., ShopMill or ShopTurn), able types they are to be assigned to. A major benefit of the Sinumerik
using a CNC high-level language The variable type defines whether ­high-level language is that it is a
offers new ways to respond quickly the variable should contain an axis built-in feature of every Sinumerik.
and flexibly. position (floating-point number, type: This means that any CNC programmer
REAL), a counter (whole number, type: can use it directly in the CNC editor
Benefits of high-level languages INTEGER) or the result of a comparison without additional software. Along-
Unlike hardware-dependent assem- (type: BOOLEAN). Control structures, side solutions for special tasks, this
bler programming, high-level com- such as conditional branches (IF, ELSE) language also offers key benefits
puter languages can be used to model or iteration loops (WHILE, REPEAT when it comes to training: working
complex program sequences in an UNTIL), are also important for the with the Sinumerik high-level lan-
easily readable format — that is, very mapping of the program sequence. guage increases the flexibility of CNC
transparently. This also applies to Beyond the basic forms of calculation, programs and gives trainees a fun­
CNC programming. CNC high-level high-level languages additionally offer damental understanding of how to
language complements machine-­ higher-order mathematical functions, handle higher-level programming lan-
dependent DIN 66025 programming such as sine/cosine or a logarithm guages. This enhances CNC training
(G00, G01, G02, …). In the CNC function. The operational scope also and increases aspiring specialists’ job
market, the Sinumerik high-level covers Boolean algebra, with functions opportunities.
­programming language offers funda- such as AND, OR and NOT.
mental properties of third-generation
high-level computer languages such Easy to prepare with flow diagrams
as C, C++, Visual Basic, Pascal or Java. When it comes to complex tasks, pro­
In practice this means that it is pos- grammers use the flow diagram tech- siemens.com/cnc4you
sible to significantly increase the flex- nique. First, the basic step-by-step [email protected]

10
 CNC 4you 2/2016

The Sinumerik high-level language

The Sinumerik high-level language includes all the
­fundamental properties of third-generation programming
languages. Following are a few examples:

Abstract data types Control structures

The following types of variables can be defined The following control structures can be used
in Sinumerik CNC programs: in the Sinumerik CNC high-level language:

INT Whole number IF, ELSE, ENDIF Conditional branch

REAL Floating-point number LOOP, ENDLOOP Infinite programming loop

BOOL Logical value FOR, ENDFOR For loop

CHAR ASCII character WHILE, ENDWHILE Program loop

STING Character string REPEAT UNTIL Program loop

AXIS CNC axis name

FRAME Coordinate displacement

Siemens AG

Siemens AG
Abstract data types in the Sinumerik CNC editor Conditional branch in the Sinumerik CNC editor

Operations in the Sinumerik CNC high-level language

The following operations can be used in CNC programs
(excerpt):

Comparative operation Arithmetic operation

== (equal to) +, -, *, /

<> (not equal to) SIN(), COS(), TAN(), ASIN(), ACOS(), ATAN()

> (greater than) SQRT(), POT()

< (less than) LN(), EXP()

>= (greater than or equal to) TRUNC(), ROUND()

Siemens AG

<= (less than or equal to)

Arithmetic operations in the Sinumerik CNC editor

11
 CNC 4you 2/2016

Perfect — and cost-effective

— profile processing
CNC knowledge

Special processes such as broaching and slotting are usually

used when manufacturing inner and outer profiles. However,
slotting can also be carried out cost-effectively on CNC turning
machines without special components.

On CNC turning machines, the work- Slotting on the turning machine mented in the programmed feed by
piece generally turns, while fixed tools A good alternative to traditional the fixed tool. The tool withdraws
such as tool bits or drill bits remove ­processes is to create the grooves or from the base of the groove at the
the necessary material. However, toothing directly on the CNC turning end of the feed movement; the back-
when it comes to special turned parts machine — particularly in the case ward movement is an empty return
with inner or outer profiles, such as of small series. It should be noted that stroke. The workpiece spindle is
gear hubs with keyways or splines, a special machine requirements must clamped tightly. The depth of the
fixed workpiece and moving tools are be met when slotting. Modern CNC groove is set by means of the x-axis
needed. Classic processes such as slot- turning machines are adapted to cope feed; the width of the groove cor-
ting and broaching are normally used with these demands thanks to rapid relates with the width of the slotting
for this. The disadvantage here is that axis movements and constant changes tool. In the case of groove widths that
the operator must change machines of direction, which are similar to those are greater than the tool width, the
during machining, resulting in greater for tapping and to the high cutting c-axis (main spindle) must be turned.
production costs. forces of solid drilling. In addition, if the groove base is to
be even, a y-axis will be required for
Traditional machining of grooves The main cutting movement in slot- lateral displacement. The machine
In mass production, optimized ting is in the z direction and is imple- requires a programmable c-axis in
machines are used for each produc­
tion process to ensure cost-effective-
ness. There are four traditional pro-
cesses: keyseating, slotting, broaching
and EDM wire cutting.

Keyseating is carried out using a draw-

knife-like cutting tool, the shape and
width of which determine the groove.
Material removal takes place in several
feeds; this process is suitable only for
through holes. With slotting, the slot-
Paul Horn GmbH

ting tool determines the shape and

width of the groove. Again, material
removal takes place in several feeds;
this process is also suitable for blind
holes. The cutting tool used for broach­-
ing is a broach with several cutting
edges sitting above one another. The
material is removed down to the final
dimensions in one stroke. Finally, EDM
wire cutting forms shapes by means
of electrical discharge machining. This
process is suitable only for electrically With slotting, the slotting tool determines
conductive materials. the shape and width of the groove

12
 CNC 4you 2/2016

Programming on the turning machine

Slotting is easy to program in the CNC control thanks to programGuide.
R variables are defined, which are used in an IF loop in the NC program.
The NC program might look like this:

; definition of R parameters
R1=30 ; diameter of hole
R2=1 ; depth of groove in X
R3=0.5 ; feed per stroke
R4=0 ; spindle position
R5=1 ; safety distance in X
R6=0 ; starting position in Z
R7=-51 ; depth of groove in Z
R10=0 ;
number of runs already
completed
order to be able to produce several
grooves on the inner or outer R11=0 ; runs required
­diameter. The tool used is a slotting R12=30 ; spindle increment angle
tool, which is defined in the tool STOPRE
management as, for example, a
front-­mounted parting tool.
; calculation
If grooves are produced on the R11=R2/R3
turning machine on a regular basis, R8=R1-R5 ;
diameter of hole + safety
the tool turret can be equipped with distance
special slotting units. The rotary
R9=R8
movement generated by the turret
drive is translated into linear move-
ment with a withdrawal function. ; NC programm
POSITION:
Creating perfect grooves
G0 SPOS=R4 G94 F5000 ; spindle starting position
CNC specialists who wish to achieve
optimum results when slotting M5
should note several things: First, the LOOP:
groove should always be created in IF R11>R10
the top of the component so that
G0 X=R9 Z=R6+R5 ; starting position in X and Z
the chips automatically fall down-
ward from the cutting edge (due to G1 Z=R7 ; stroke to feed depth
gravity). Sufficient cooling is required G0 X=R8 ; withdrawal
during the slotting process for better G0 Z=R6+R5 ; back to starting position
material removal. In addition, plenty
R9=R9+R3 ;offset of safety distance +
of scope for ejection must be ensured
depth of groove
in through holes or undercuts in
blind holes, to prevent breakage of R10=R10+1 ; run counter
tools or damage to turned parts. GOTOB LOOP
ENDIF
Slotting can also be carried out on a
R4=R4+R12
milling machine or machining center.
In this case, the tool is clamped in R10=0
the fixed milling spindle. IF R4<360
GOTOB POSITION
ENDIF
M30

siemens.com/cnc4you
[email protected]

13
 CNC 4you 2/2016

The cutting
CNC knowledge

edge of
productivity
Polygon turning is becoming more and
more common in high-output series
production of flats. One prerequisite for this
is suitable turning machines and tools, as
well as a CNC control system that supports
synchronous spindle coupling.

Driven tools are being used on turning machines in

more and more fields of application. The milling of flats,
such as polygonal pins, has even become the state of
the art. The only drawback to this process is the time
that it takes, making efficient implementation difficult
in mass production. For this reason, the use of inno­
vative polygon turning in CNC turning centers is increas­-
ing. This is a continual process, similar to conventional
turning, which allows users to halve machining time
compared with milling. Time savings of up to 90% are
possible with materials that are easy to machine.

Cutter in sync with the main spindle

In polygon turning, even surfaces — such as parallel
flats or polygons (with three to eight sides) — are
­generated on the lateral surface of rotation-symme­trical
workpieces using a cutter. The workpiece (the main
spindle) and the rotating tool (the cutter) work in a
­s ynchronous coupling relationship, creating even
­surfaces. The number of surfaces generated depends
on the translation relation and the number of cutting
edges on the cutting tool. The workpiece and tool
rotate in opposite directions. In practice, a translation
relation of 2:1 is often used. This means that the cutter
turns at double the speed of the workpiece. One
cutting edge always works on two opposite surfaces.
Accordingly, a tool with two cutting edges is used to
Paul Horn GmbH

turn a square, a tool with three cutting edges is used

to turn a hexagon and so on. If the translation relation
In polygon turning, even surfaces are generated on the lateral is different, or if a different number of cutting edges
surfaces of rotation-symmetrical workpieces using a cutter are used, surfaces may be very convex or concave.

14
 CNC 4you 2/2016

The synchronous spindle function should be used in Radial and axial processes
the Sinumerik to ensure coupled, synchronous opera- Depending on the workpiece, the radial plunging proce-
tion of the main spindle and tool spindle. One spindle dure is used for flats, and the axial longitudinal turning
must be defined as the leading spindle and the second procedure is used for polygons behind a flange. These are
as the following spindle. The two spindles work syn- programmed using stock removal cycles combined with
chronously in terms of position and speed. The cou- the contour editor, or in G-code.
pling must be defined and activated in the program
before machining and then deactivated and deleted siemens.com/cnc4you
after machining. [email protected]

Programming example: synchronous spindle

COUPDEL (S2) ; possible couplings delete

COUPDEF (S2,S1,2,-1,"NOC","DV") ; coupling define

; S1 is the main spindle
; S2 is the driven tool
; Translation relation 2:1
; Portents for treatment direction

COUPON (S2) ; couplings switch on

; … ; now the real treatment occurs

COUPOF (S2,S1) ; couplings switch off

COUPDEL (S2) ; coupling delete

M30
Siemens AG

Synchronous spindle coupling

15
 CNC 4you 2/2016

Siemens AG

Mold making
Motorsports have always been an
important part of life for Klaus Mur-
nauer, now the owner of KME Renn-
technik. As a young boy, the qualified

for racing
auto mechanic and mechanical engi-
On the shopfloor

neer watched wide-eyed as fast cars

sped around the track. During his
studies, training and first few jobs,
he learned about the design of motor
vehicles and the various areas of
For nine years, KME Renntechnik has been mechanical engineering. Today, as
supplying several different racing teams. owner of KME Renntechnik, Murnauer
can draw on this experience when
With flexibility, quality and speed in CNC designing and producing molds and
production for mold making, the company parts used in the chassis, engines,
gears and other components of race
helps secure success on the racetrack. cars. His thriving company currently
has six employees and has made a
good name for itself among many
racing teams. Owner Murnauer says
proudly: “Parts that we have produced

16
 CNC 4you 2/2016

»These machining centers

equipped with Sinumerik
have the best price/perfor-
mance ratio on the market
for my needs.«
 laus Murnauer,
K
Owner and Managing Director, KME Renntechnik

Siemens AG
Klaus Murnauer has been won over by his
two five-axis machining centers with
Sinumerik 840D sl and Sinumerik Operate

Short throughput times thanks out the two Spinner U5-620

to man and machine five-­axis machi­ning centers with
What is this success based upon? Sinumerik 840D sl and the user inter-
The entrepreneur believes the answer face Sinumerik Operate, which were
lies in the company’s extensive exper- acquired in 2012: “These machining
tise, as well as flexibility and short centers equipped with Sinumerik
throughput times. Customers have have the best price/performance ratio
long considered compliance with on the market for my needs.” With
accuracy and quality requirements component complexity growing, 2+3
to be a given. The manufacturing axes are extremely helpful, as it means
expert explains what he means by that machining can usually be carried
short throughput times by using the out in one clamping operation. The
KME Renntechnik has made a name
for itself with molds, tools and finished example of versions of a complicated result is greater precision with shorter
parts for motorsports laminating tool: “To start with, we ­through­- put times. “We are also
work with the customer to define getting more and more requests for
the size and form of the component, parts with free-form surfaces. Thanks
while we are at the same time acquir­- to the U5-620, that’s no problem
ing the material. If it’s a complicated for us. This is because we can have
are used in all DTM brands and can component with free-form surfaces, the five axes of the milling machine
also be found in Formula 1. Just we design and program it on our running simultaneously,” explains the
recently we received a big order from CAD/CAM system, save the program manufacturing expert.
a well-known racing team that will to Sinumerik 840D sl via the network
be entering its vehicles into the next and launch our Spinner U5-620 simul- Five-axis machining and high-end
24 Hours of Le Mans.” taneous five-axis machining center.” control system for top quality
At the end, all his employees have to On the U5-620, a tool magazine
Molds, tools and finished parts do is draw- or mirror-polish the pre- with up to 55 spaces and a dual-arm
offering the highest precision and cisely machined laminating tool and tool changer minimizes idle time, and
reliability are KME’s trademark. install it as required. “Depending on axis accelerations of 5 m/s² increase
The company works with metals as the complexity, we only need three to productivity. The digital position
well as plastics and carbon. This is five days for the entire process,” adds ­measuring system ensures high work-
one reason other sectors have also the KME boss. piece accuracy. The machines achieve
become aware of the company based positioning accuracies of Tp max.
in Rott am Inn, Germany. Racing This is made possible by the fact that = 10 μm in the machining area and
­dominates the company’s business, all his employees are well coordinated repeat accuracies of up to 3 μm in
at just under 70%, but firms from and work in 24-hour shift operation if the individual axes.
the medical technology and aero- necessary. KME also sees the machine
space sectors (certification for air- tools, based on Siemens control system Murnauer cannot make any general
plane parts is already underway) technology, as a key factor in the statements regarding surface rough-
are gaining in importance. ­com­pany’s success. ­Murnauer singles ness, emphasizing that it depends on

17
CNC 4you 2/2016

Siemens AG
Various parts are manufactured using
different materials and are used in the chassis,
bodywork, engines and gears of race cars

the different materials, feeds and Optimum operability for experts

f­ eed rates. But he does provide one and “lateral entrant” employees
practical example: “When finishing The head of KME is clearly also Siemens AG

high-strength aluminum, we often delighted with the ease of operation

use a 10-mm ball cutter, which turns and programming facilitated by From left to right: Alois Penzkofer,
at 10,000 min –1 and works at a depth Sinumerik Operate. Cutting machine user support and promoter at
and side feed of 0.5 mm, with a feed operator and CNC programmer Siemens; Klaus Murnauer, owner
of KME Renntechnik; and Maik
rate of around 12 m/min. The surface ­A le­xan­der Neumaier, for example,
Fritsche, sales employee at Böhm
values of R a = 0.5 μm to 0.8 μm often was skeptical when he first joined Werkzeugmaschinen GmbH, are
requested by our customers cannot KME and saw that the company used delighted with the successful
be achieved directly — however, only Siemens CNCs. He had been collaboration
­postprocessing by hand, which takes ­programming machines using another
only a few minutes, is enough to manufacturer’s CNC for 10 years.
take us safely into the target range.” And now? His reservations disap­
peared after two days: “I didn’t believe
Alongside stable machine design, I would be able to program and set here, because in this mode the CNC
the top-quality control system and things up more quickly with Sinumerik requests each individual command
drive technology from Siemens is a Operate than with my old control and models it visually. This means
great help here. KME uses the new system after such a short time. I now the operator is guided swiftly and
version of the Sinumerik MDynamics create complete 3+2-axis programs accurately from the first to the last
milling technology package with the directly on the machine.” programming step. Plain text hints
Advanced Surface intelligent motion provide assistance in the event of
control. The engineers have further The modern user interface is also uncertainty. Errors are extremely
optimized the Look Ahead function advantageous for “lateral entrants” — unlikely, as trained screed installer
and integrated an efficient data employees coming in from different Georg Schartner confirms: “Although
­compressor that aligns the modeled sectors — upon whom companies are I come from an entirely different
individual points so well during pro­ becoming increasingly dependent sector, I managed to program my
gram generation that the machine due to the acute shortage of skilled first few small parts independently
can mill extremely smooth surfaces. workers. The reason? Contract manu- and fault-free after just one day.”
The manufacturing expert also finds facturing companies expect produc-
the intel­ligent jerk control helpful. tion workers to be able to program
It means that the axes are sped up simple components directly on the siemens.com/cnc4you
and slowed down gently, despite machine tool. The ShopMill graphical kme-renntechnik.com
extreme dynamic response. work-step programming system helps [email protected]

18
 CNC 4you 2/2016

Industry news
IndustryArena GmbH

Happy birthday, The modern new building

IndustryArena!
of the Industry Competence
Center in Langenfeld,
Germany, with more than
1,000 m2 of office space

What started as a hobby for CNC user and consultant Frank Nolden is
today the largest online skills network in the industry — IndustryArena.com.
This year the industry community is celebrating its 15th birthday.

Just as young people can hardly the forum to an international level; step in its development and has
imagine a world without smartphones, then in 2009, he professionalized the become IndustryArena.com, address­ing
for many CNC practitioners, a world support offered by creating a limited a wider range of topics. In 2016, the
without IndustryArena.com is incon- liability company with the involve­ forum’s anniversary year, Nolden’s
ceivable. But it has not been around ment of the industry association team, now with more than 20 full-time
forever. Just 15 years ago, there was VDW (German Machine Tool Builders’ employees, is moving to a new, ultra-
no way to rapidly communicate with ­A sso­ciation). In 2013, he established modern office in Langenfeld, Germany.
colleagues from other companies a ­partnership with the US forum
about problems in CNC machining. CNCZone.com, which he then took The CNC Arena and IndustryArena
Frank Nolden changed all that. In over in 2016. In 2015, he acknowl- forums have changed the industry.
his free time, and on his own at first edged that the world of CNC produc- They have brought users closer
but then later along with other like- tion could no longer remain an island together but also closer to suppliers.
minded users, he launched today’s and that it had to start networking What more is there to say? The Siemens
leading industry forum under the with other production processes. The Sinumerik team says c­ ongratulations
name CNC Arena. In 2006, he took result: CNC Arena has taken a further and thank you!

19
 CNC 4you 2/2016

Facebook for CNC professionals

An interview with Frank Nolden about the early years and the future of the forum

Mr. Nolden, how did you come up How did you come up with the
with the idea of starting an online name CNC Arena?
forum for CNC users back in 2001? Frank Nolden: It was quite literally
Frank Nolden: Actually, it happened staring me in the face: the topic was
in the usual way: I was looking for CNC, and, living in Cologne, I saw
a solution to an urgent problem in the Cologne Arena on an almost daily
a production sequence. At the time, basis. It wasn’t a strategic consider-
I was working as a CNC solutions ation, more of a gut decision. But it
­consultant, and I saw all the problems worked well.
practitioners were experiencing in
companies. They were left to their What were the biggest challenges
own devices, as there was no com­ when the forum started?
IndustryArena GmbH

munication between users at various Frank Nolden: There was the fact
manufacturing companies. And at the that to begin with, I had to do every-
same time, the work, machines and thing on my own and alongside my
processes were becoming increas- job. During the day, I advertised to
ingly complex. The only information CNC users at the companies I visited
»We need a skills source for users was the suppliers — as a consultant, using homemade
network for the entire and CNC users did not always get information flyers. Then at night, I sat
industrial production answers from them within a reason- in front of the computer. I really did
able time frame or that fully answered have to develop everything myself,
sector — and their questions. That’s when I came and I also monitored the content of
that’s exactly what across the first travel forums, where the forums. I then gradually found
IndustryArena travelers could share information on volunteers to support me with the
the Internet. That gave me the idea monitoring, some of whom still work
is intended to be.« to start up a similar forum for CNC for us to this day. Of course there
Frank Nolden, users — an information and dialogue was resistance, and I couldn’t always
Founder, IndustryArena.com platform for like-minded people. count on cooperation. Quite the

With more than 450,000 registered users worldwide to date, IndustryArena.com is one of the largest online skills networks in the world

Membership growth between 2001 and 2015

2013 2014
approx. 87,000 members 350,000 members

2011
approx. 70,000 members
2008
2015
approx. 50,000 members
400,000 members

2005
approx. 31,000 members

Forecast for 2016

2003 approx. 500,000 members
approx. 24,000 members

2001
approx. 9,000 members
Publicis Pixelpark

20
 CNC 4you 2/2016

­ pposite, in fact: people who wanted

o
discussions and an exchange of infor-
mation with other companies were
seen as “spies.” Neither the users nor
the manufacturing companies, and
especially not the suppliers, were
­prepared to openly share information
back then.

How did you finance it?

Frank Nolden: To begin with, it was
just an expensive hobby. And even
for my first helpers in monitoring the
forums, it was nothing more than
that. We all sacrificed a lot of free time
and money back then. But there was
always one thing that remained
important to us: the forum had to

Siemens AG
be free for CNC users. And that is
how it has stayed to this day. Gradu- The free forum helps users with various questions relating to Sinumerik
ally, we got our first sponsors from
the industry. Siemens was one of the
first companies to support us as a Today, practitioners are facing new well as suppliers, a great deal of
sponsor. And it always remained clear: challenges: digitalization, networking, added value here. We always focus
the ­companies were not to have any Industrie 4.0. By changing our name, on ensuring that users also benefit
­influence on the forums or access to we want to show that the world of from improved communication with
addresses. Today, we have more than CNC-based production is not an island. suppliers.
3,000 ­companies as partners. These Machining technology remains the
com­panies can provide information in foundation, but we practitioners need What are you most pleased about
various ways — for example, via our to network, communicate with other in terms of the development of the
social media newsroom, webinars, job areas of industrial production, and forum?
portals, information materials and so represent process chains that are both Frank Nolden: I think we have been
on. But we always keep a close eye inte­grated and highly flexible. We able to really change the way we
on the user forums to make sure they need a skills network for the entire ­communicate in our industry, and our
remain free of influence, and we take industrial production sector — and forum helps many users on a daily
strict action in the event of any abuse. that’s exactly what IndustryArena is basis. All this is still free to users. And
Since 2009, the monitoring has been intended to be. it allows for professional dialogue.
carried out professionally by a limited Of course, there are occasional angry
liability company with the involve- On the occasion of the forum’s users in the forum who need to vent
ment of the German Machine Tool anniversary, you opened your new their frustration and stress. However,
Builders’ Association. Since then, I’ve office in April… thanks to our extremely experienced
essentially turned my hobby into a Frank Nolden: Yes, more than 1,000 m2 moderators, we are able to resolve
job — what more could a person of state-of-the-art office facilities. these issues in a targeted manner.
want? We have developed into a full-service We then communicate with the com-
agency for communication with users. panies and bring specific users and
In 2015, you renamed the platform Our ICC — Industry Competence suppliers into a personal dialogue —
IndustryArena.com. Not all CNC Center — offers space for seminars, sometimes even away from the
users and partners thought it was a workshops and conferences. And, forum. And that’s precisely why we
good move. What were your reasons in addition to the virtual forum of always collect real names and tele-
for doing this? IndustryArena.com, we also want to phone numbers when users register
Frank Nolden: Even when CNC Arena establish a real-world communication with us. The fact that no one except
was founded, what I wanted to do space here. We advise companies us uses these details is what sets
was give users the knowledge they and help them communicate with us apart from many modern social
needed to perform their day-to-day users and customers in a more modern, platforms. I’m really proud of that,
work. And I wanted to do it so quickly effective and, most importantly, too. IndustryArena.com has proven
that it could actually be used in their open way. We organize events, we extremely useful for users, which is
day-to-day work. Our team wanted produce videos, and we have a maga- precisely what I wanted when I set
to pool the expertise of all users, zine and develop websites. Thanks up the forum.
so that they could master the increas- to our long experience as operators
ingly complex work processes in of IndustryArena.com, we are able to siemens.com/cnc4you
the CNC-based production sector. offer users and manufacturers, as [email protected]

21
 CNC 4you 2/2016
Education and
training

Finding the best

Fotolia Daniel Nahabedian

in class Abu Dhabi, one of the most

modern cities in the world,
awaits the participants of
WorldSkills 2017

At the 2017 WorldSkills competition in Abu Dhabi, more than 1,200 young
professionals from 72 national teams will take part in 50 competitions,
including CNC-based milling and turning. The national qualifiers are currently
under way, providing an excellent opportunity for CNC4you to take a look
behind the scenes at the competition.

Abu Dhabi, the capital city of the of WorldSkills Europe, who under- land at WorldSkills 2015 in São Paulo,
United Arab Emirates, is the venue stands the importance of the skills Brazil. Can companies also benefit
for WorldSkills 2017, which will take compe­t ition and the trends better from WorldSkills?
place from October 14 to 19 next than anyone.
year. How important is the compe­ Elias Kalt, production manager at
tition in terms of training, and why How do young professionals get into Swiss medical device manufacturer
is the level of involvement of various these competitions, and how do they Hamilton Bonaduz AG, which has
companies and countries so differ­ prepare for them? What is it like to per- been sending trainees to the compe­
­e nt? We put these questions to sonally participate in the WorldSkills titions for many years, explains why
Hubert Romer, managing director of mega-event? We spoke about this with he is convinced that this is a worth-
WorldSkills Germany and president Tizian Ulber, who represented Switzer- while investment in the future.

22
 CNC 4you 2/2016

A real benefit
Mr. Romer, looking at WorldSkills
in the different countries, it’s
immediately clear that the compe­
titions have very different levels
of significance. Why is that?
Hubert Romer: Yes, the differences in
attendance figures for the apprentice-
ship programs represented and the
»WorldSkills
involvement of the various countries
are very significant. A major reason is
is a career
that the competitions are organized
very differently at the national level.
booster.«
In Switzerland and many European Hubert Romer, Managing Director,
WorldSkills Germany; President,
agentur kmr

countries, the competitions are affili- WorldSkills Europe; and Delegate,

ated with the chambers of industry WorldSkills International
and commerce and are financed by
the private sector. In Asia, they are
seen as a national competitive sport
and are state run and financed.
studies show that participants develop Hubert Romer: That does not reflect
…and in Germany? an ability to work under pressure, the experiences of the companies
Hubert Romer: In Germany, and in leadership and decision-making abili- taking part: the competitions increase
particular in German industry, the ties, and character, and they also loyalty to the company. The young
competitions have not yet gained the create networks. All these are quali- champions gain a great deal of addi-
importance and status commensurate ties that companies are urgently tional experience in their preparation
with our global economic significance. seeking these days. We use scientific and in the competitions, which is a
WorldSkills Germany is a registered research to follow the professional real benefit when they return to the
association with around 70 members development of our participants, and company.
from trade and industry. Although we can see that WorldSkills is a career
companies such as Siemens are getting booster. You have been involved in the
involved here, there is a lack of major professional championships for
support from businesses and the state. What advantages do you see for many years. Where do you get
That sets us back somewhat by inter- companies that send their trainees your energy and what drives you?
national standards. to the competitions? Hubert Romer: I see the competi-
Hubert Romer: There is a long list tions as a form of intercultural under-
How can the situation be improved? of advantages, not least of which is standing on an international scale.
Hubert Romer: We need to provide publicity for the profession and the One of my best memories was seeing
even better information and reach significantly higher level of awareness Israelis and Palestinians working
out to companies and young trainees of the company in the region. In together so well in different skill
more aggressively. The fact is that Germany, companies are suffering areas at WorldSkills as well as in
companies that have participated from a skills shortage — awareness training. Personally, I find the idea
once immediately become firm believ­ helps attract young people to the of these competitions very compel-
­ers and take part again and again. company, and a good reputation as a ling because I have seen the com­
And I want these skills competitions training company also generates new petitive mentality that the young
to become a third pillar in apprentice- business. All these effects are clear. people gain by taking part. The
ships, alongside the education and ­competitions bring out the best in
work aspects. Many small companies are afraid the trainees — and there is so
that they will lose good trainees if much more to them than many older
Why is that so important? they become known through the people like to believe.
Hubert Romer: Learning for and competitions. How do you respond
during a competition is different. Our to these fears?

23
CNC 4you 2/2016

»I benefited immensely,

both professionally and
personally.«
Tizian Ulber, Mechanician Operator, Hamilton Bonaduz AG,
and SwissSkills Champion 2014 and WorldSkills Participant

Siemens AG/P. Kronfeld

2015 in São Paulo

Meeting tight deadlines

The SwissSkills competitions toward solutions under extreme pres- Tizian Ulber: The participants were
are generally very important to sure. The training was so great that given a 2D drawing that they had
Swiss companies. How are the I even attended additional sessions. to transfer to a program, and then
national qualifiers organized? they had to produce the workpiece.
Tizian Ulber: Almost 7,000 apprentices And what sort of support There were more than 20 machines
took part in 2015. That includes around did you get from your company? running in parallel, with a com­
60 trainees in the CNC pro­fessions. Tizian Ulber: The support at petitor working on each of them,
The first round starts at the companies. Hamil­ton was excellent. Hamilton all trying to produce the workpiece
All the participants are given practical bought the same machine that we fault-free in six to seven hours.
tasks, and then the top 24 are invited would work on in Brazil: a Romi 800 More than half the participants
to take a theory exam. The top eight with Sinumerik 828D. Up until that failed just because of the time con-
performers in this exam then compete point, Hamilton had never worked straints. And the workpiece itself
in the ­SwissSkills championships. This with Sinumerik before. Even before was extremely complex — full of
event in itself was great. All of Switzer- the machine was installed, I received lots of difficulties.
land was watching. It was a fantastic support from Siemens: not only was
experience! I given Sinutrain licenses to practice What did you take away with you
with, but Hans Küng from Siemens from these competitions?
…and in 2014 you were crowned Switzerland also gave me a huge Tizian Ulber: I benefited immensely,
Swiss champion. amount of support throughout the both professionally and personally.
Tizian Ulber: Yes, that was a great whole period and answered any My training was already very good.
success. My instructors and I were ­questions I had. But thanks to the competition, I was
absolutely delighted. And more than able to enjoy additional training
40 SwissSkills champions from the …and in Brazil? ­s essions. In an apprenticeship you
various competitions qualified for Tizian Ulber: It was kind of like the work in a protected environment,
WorldSkills. Together, we made up the Olympic Games. There was an opening whereas the professional champion-
Swiss national team for São Paulo. ceremony where all the national teams ships are very clearly a competition.
paraded in front of more than 10,000 This competition is probably worth
What happened then? spectators. A really cool experience. 10 years of professional experience.
Tizian Ulber: The national team And it goes without saying that
learned about the competitions What happened during the actual ­t raveling to Brazil as a national team
during a total of five preparatory competition then? You achieved with so many young people was
weekends. We were also given mental a very good seventh place. What incredibly cool. I wholeheartedly
training, so that we could work tasks did you face? ­r ecommend it.

24
 CNC 4you 2/2016

A worthwhile investment

Mr. Kalt, for how long has your And are investments like that
company been sending trainees to worthwhile?
the championships? Elias Kalt: Yes, we are convinced that
Elias Kalt: It was a management ini- they are. And the core issue here is
tiative in 2005 that prompted us to not the championships but a good
enter the competitions. That’s why we apprenticeship. Tizian was a great
have been taking part in SwissSkills advertisement for us. Thanks to the
regularly since 2006, with several additional courses at Siemens and The full versions of the interviews
trainees from various apprenticeships. other manufacturers (Fraisa, x-data, are available online at
etc.), he learned a great deal about www.siemens.com/cnc4you
And Hamilton actually won a new technologies and processes in For more information about
Swiss championship with Tizian. preparation for the competition. He WorldSkills Germany, go to
We’ve heard from him that you also learned to work under extreme www.worldskillsgermany.com
even invested in a new machine pressure. He and the participants
for WorldSkills? from other age groups have brought
You can find more information
Elias Kalt: Yes, that’s right. As a back all this experience to our
about the competitors at
SwissSkills champion, Tizian was company. And we all benefit from
www.worldskills.org
­eligible to participate in WorldSkills. that here. The competitions are
We wanted to do our part to make an incredible experience for the
sure he was well prepared to repre- trainees, but the companies are siemens.com/cnc4you
sent our company and country. clear winners too. [email protected]

»We get a lot in return.«

Elias Kalt, Production Manager, Hamilton Bonaduz AG
Hamilton Bonaduz AG

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 CNC 4you 2/2016

When Reiner Rohde founded R&D Steuerungstechnik with

his business partner in 1974, he was still developing his
own control systems, there was no talk of retrofitting for
other manufacturers. It was only in 1996 that he said yes to
Siemens — the start of a successful partnership. R&D now
delivers 20 to 30 retrofit projects per year, and with more
Industry news

than 300 projects under its belt, the company has a reser-
voir of considerable experience. Customer motivations
are varied — for example, customers from the automotive
industry want retrofitting to maintain the stability of their
processes. This allows OEMs and suppliers to save costs and
time that would otherwise be spent on adapting and recer-
tifying processes.

Considerable experience required

Other customers choose a retrofit because they wish to
maintain the often excellent mechanical qualities of their
existing machines. This was the case for a 20-meter-long
Tacchi heavy-duty turning center for turbine production,
which takes up practically the entire R&D factory hall.
Sacha van Ool explains: “The mechanics and performance
characteristics are already fantastic, but we are going to
take the system to a whole new level in terms of electrics,
control system and sensor technology.” Heavy machine
tools are a specialty of the retrofitters at R&D. Here it is not
simply a question of modernizing the control system; this
area demands experience in new construction or repro­
duction of mechanical parts and much more. For example,
picking up and redelivering the objects to the customer,
or commissioning at the customer’s location, can involve
extreme logistic challenges. Project terms of way over a
year are not uncommon.

Individual concepts
The company’s experience in retrofits has become more
and more important in recent years; informal application
and process knowledge is being lost because experienced
operators are retiring from their companies. Detlev Gunia,
R&D Steuerungstechnik GmbH & Co. KG

managing director of R&D, describes the opportunities

that retrofit projects provide in this instance: “We can
produce operating concepts that are more closely related
to the process and provide better instruction for new oper-
ators — about software-supported operator guidance and,
in some instances, about the development of company-­
R&D Steuerungstechnik specializes in the retrofitting specific operator panels.” Most of these projects use the
of heavy machine tools Sinumerik 840D sl control system, which is easy to operate
but is stretched to its limits when it comes to special pro-

Retrofit in XXL
cessing, special tool implementation or requests for custom-
ized operating menus. By developing special cycles with
appropriate operator guidance, R&D can implement most
customer requirements of this kind. “I am happy that we
chose Sinumerik back then. With more than 120 employees
in various areas of the company, we handle retrofit projects
R&D Steuerungstechnik GmbH & Co. KG in both large and small and share this practical experience with
Mönchengladbach, Germany, is marking developers from Siemens — an extremely valuable partner-
ship for both parties,” explains Gunia on the occasion of the
an anniversary: this versatile company 20th anniversary of the R&D-Siemens collaboration.
has been delivering retrofit projects for
Sinumerik-controlled CNC machines for siemens.com/cnc4you
20 years. [email protected]

26
 cnc4you 2/2016

Tips and tricks

News
Those looking for useful tips and tricks
relating to machine tools and CNC
machining with Sinumerik or insider
­information on CNC technology will find
what they are looking for in the CNC4you
portal. The contents of this edition have
been newly added and include high-level
­languages, slotting and polygon turning.

All tips and tricks are available at a glance

and can be accessed at any time at
Siemens AG

sie.ag/2b04Vym

Production planning with Sinutrain

CNC users can prepare for machine work with the Sinutrain for Sinumerik
Operate offline programming station, using just a standard PC or laptop. Custom-
ized packages are available for both production planning and training. The new
Sinutrain versions replicate the software Version 4.7 SP3 and Version 4.5 SP6,
which enables employees to work in a familiar environment. Sinutrain allows
for realistic operation through the use of Sinumerik Operate and an animated
machine operation panel.

With the new software versions, the user can gain a quick overview of the entire
machine, as it is now mapped virtually on the Sinutrain interface (“workbench”
framework interface). Sinutrain can also be adapted to match the real machine.
This allows the real machine control system’s configuration (e.g., axis configura-
tions, cycles) to be mirrored in Sinutrain.

Download the free basic version at siemens.com/cnc4you.

Siemens AG
siemens.com/sinutrain

Dates

BIMU October 4—8, 2016 Milan, Italy

JIMTOF November 17—22, 2016 Tokyo, Japan
IMTEX January 26—February 1, 2017 Bangalore, India
Turning Days February 14—17, 2017 Friedrichshafen, Germany

You can find an overview of additional trade fair dates and

training courses in the Events section of the CNC4you portal.

sie.ag/2ahgtdxA

27
Stay up to date with CNC4you
Visit siemens.com/cnc4you for more
information about current news and to
download manufacturing instructions
for the latest workpieces.
Subscribe to our info mailing to ensure
you don’t miss out on any news:
siemens.com/cnc4you-infomailing
Would you like to read CNC4you news
on the go? Then the CNC4you app is what
you need: siemens.com/cnc4you-app

Published by
© Siemens AG 2016
Digital Factory
Gleiwitzer Straße 555
90475 Nuremberg, Germany
For further information please visit:
siemens.com/cnc4you
siemens.com/sinumerik

Contact: [email protected]
Article No.: E20001-A1920-P610-X-7600
Printed in Germany

Subject to changes and errors. The infor­

mation given in this document contains only
general descriptions and/or performance
­features, which may not always specifically
reflect those described or which may undergo
modification in the course of further develop-
ment of the products. The requested perfor-
mance features are binding only when they
are expressly agreed upon in the ­concluded
contract.

ShopMill, ShopTurn, SINUMERIK, and SinuTrain

are registered trademarks of Siemens AG.
Any unauthorized use is prohibited. All other
designations in this document may represent
trademarks whose use by third parties for
their own purposes may v­ iolate the proprietary
rights of the owner.