The EMCOnomist[NOV/2009]

Innovations at the EMO: page 5

Grundfos - Everything's flowing nicely: page 6

EMCO's technology solutions: page 10

[Discover the Variety of EMCONOMY]

[The EMCOnomist ] Editorial

After the crisis is before the crisis.After the EMO is before the EMO. Havewe learned anything over the last 12months? Are we fully prepared to facethe months ahead?The questions being asked at the EMOin Milan were the same as those underdiscussion at every industry event. Andno wonder: everyone is currently busyadapting to the new conditions and asyet, no one has discovered the genericformula for success. This is becausethere simply isn’t one. Instead, compa-nies have to decide where to focus theirenergies – and the best option is still tofocus on the customer. EMCO is livingproof of this. We work out where actionneeds to be taken via customer surveysand through day-to-day communica-tion between potential clients, existingcustomers, and our sales and customerservice teams and then adapt ourongoing developments and currentstructures accordingly. In this way, theEMCO sales team can quickly and sen-sitively identify market demand andtrends and provide the R&D departmentwith useful input. As a result, three impor-tant, strategic new products were readyin time to present at the EMO: theMAXXMILL 500, a new vertical 5-axismachining center; the EMCOMILL E350,a highly compact vertical 3-axis machi-ning center; and the HYPERTURN 45,a high-performance turning center forcomplete machining with a bar capacity

of 45 mm on both the main spindle andcounter spindle. Intelligent, efficientautomation solutions are currentlybeing developed alongside theseproducts. We know that only thosewho can offer both simple and flexibleautomation for their machines will beable to succeed in the future. This ideais explored in more detail in the articleabout our long-standing customerGrundfos on page on page 6 and 7.With product solutions designed pre-cisely to meet the market requirementsand as a streamlined, powerful organi-zation with its eyes and ears open tonew ideas, we are ready for whateverdevelopments come next – whether thecrisis turns out to be U, V, or, in theworst case, W-shaped. One thing hasbecome clear: we will not be able toachieve results at the same level as2008 in the near future. Over the nextfew years, the industry will manage toperform at its 2005/2006 level. Whetherand to what extent this will workdepends heavily on our ability to thinkup new strategies and to act on themconsistently, to question the validity ofknown causes and effects, to rejectfalse truths, and to look for and findcreative new approaches.

[2]

A-TEC Industriessemi-annualreportSolid figures despite the challenging market environment

The company’s second-quarter perfor-mance was broadly the same as that ofthe first quarter, but the impact of theeconomic crisis worsened for some ofour businesses. However, on a positivenote, the first signs of a pick-up indemand emerged in June. Whether therecovery will be sustainable remainsto be seen, because many customerswill probably have reduced their stockstoo dramatically.

The plant construction division wascushioned by its order backlog, allo-wing comparatively stable results tobe achieved both this year and in 2010.In addition, however, this division washit by a dramatic decline in order intakecaused by postponed projects andclients’ problems obtaining finance.The secondary copper extraction busi-ness in Brixlegg posted a positive per-formance.Around 40% of the respective results ofthe drive technology and machine toolsdivisions are still fully exposed to the

Guided by our customersDr. Stefan Hansch

PEOPLE [The EMCOnomist ]

economic cycle. In the industrial motorsand smaller machine tools divisions,the market took an overall nosediveand has stabilized at a low level.

Mirko Kovats, the CEO of A-TEC Indu-stries AG summarized: „All in all, wecan say that we have achieved a solidperformance in a difficult market envi-ronment.“The latest expert economic forecastspromise a slight improvement, withAsian markets such as China and Indiain particular emerging as the main eco-nomic driving forces. According torecent estimates, the North Americaneconomy seems to have stabilized, withEurope following slightly behind.Kovats added: „I see this as anothersign that the future growth markets areto be found in Asia and that increasedengagement in these markets will cre-ate the most value.“

Year-on-year figures

In the first half, sales revenues fell by 9.7 % to EUR 1,462.7 million, causedmainly by the 46 % decline in the mine-rals & metals division, driven by thelow price of copper and the generalreluctance to invest that has accom-panied the latent economic crisis. Inthe same period, the EBITDA rose by4.2 % to hit EUR 94.4 million despite theeconomic crisis, due to the divisions’solid operational performance.

Market and product development for the EMCO Group

Demand for new EMCO machinescontinued to be slow in the secondquarter of 2009. The training sectorproved more resistant to the crisis, whichcaused price competition to grownoticeably more fierce. Positive signalsand growth are most likely to occur inemerging markets in Asia and SouthAmerica, which have a high demand formanufacturing technology. Other indu-

stries which are less significantly affec-ted by the state of the economy, suchas the large mechanical engineering,medicine, energy technology, and rail-way construction sectors, also offerpotential. The EMCO Group is therefore

currently focusing its market activitymore strongly on these areas.The methods used by EMCO to in-crease demand (events, new products,and so on) are described further on inthis edition of ‘The E[M]COnomist’.

Mauro SalvadoriMauro Salvadori became managing director of EMCO Italy andEMCO FAMUP on December 1, 2008. His focus in this role lies onthe one hand on expanding the EMCO Group’s market presence inItaly and, on the other, on using the synergies between productionsites in Italy and Austria to even greater advantage. His many years of experience within the industry have prepared Mr. Salvadori for this challenge. As Managing Director andOperations Manager for Cinetic Guistian Grinding, he was respon-sible for major business developments in Southern and CentralEurope, China, and Russia.

Walter VoitAs of September 1, 2009, Mr. Walter Voit will assumed the role ofsales director industry for the EMCO Group. In this role he isresponsible for, manages, and coordinates all sales staff incountries in which no subsidiaries are based. In the countries inwhich subsidiaries are based, he has an advising and supportingfunction. Since 1987 Mr. Voit has successfully held various roles atEMCO – most recently as sales director for Western Europe andGermany. His wealth of experience in the company’s most centraldivisions has put him in an excellent position to make the salesteam even stronger and more successful.

Christoph WernzEngineer Christoph Wernz took over as head of the Research andDevelopment division for the EMCO Group on April 1, 2009. Hegrew up in Oberndorf am Neckar in the German state of Baden-Württemberg and studied mechanical engineering in Stuttgart, spe-cializing in factory machines. He first proved his skills while wor-king as a research assistant for Professor Heisel at the Universityof Stuttgart for three years. Mr. Wernz gained industry experienceworking as a construction and development manager for Emag fornine years and then as a technical director for Matec in Köngen fortwo years.

Zdenek PileckyAs of Novemver 1, 2009, Mr. Zdenek Pilecky is assigned sales andservice manager for the Czech Republic and Eastern Europe atEMCO Intos. Therefore, he is responsible for all sales and serviceagendas for the entire product range as well as for the develop-ment of a sales and service center for Eastern Europe. Mr. Pileckyhas experience in engineering and recently worked as regionalsales manager for milling machines at Schwäbische Werkzeu-gmaschinen GmbH.

A hip joint socket for the medicalindustry was prepared using theMAXXTURN 45 as a demonstrationpiece. The stainless steel workpiecewas created from the bar stock in asingle machining process.

The HYPERTURN 665 PowerMillwith a milling spindle and a B axisdemonstrates the simultaneous5-axis machining of an impeller.This requires extremely accurateand dynamic interpolated axes.

A complex workpiece for the aviationindustry was manufactured in theHYPERTURN 690 PowerMill. Theworkpiece was fully machined in asingle process. Complex milling operations, a large chip volume, andlarge drilling capacities meant thathigh levels of stability and drivepower were required.

Another, much larger impeller wasmilled in the LINEARMILL 600 HD.The part was machined using 5 simultaneously interpolated axes.

The EMCOTURN E45 with its swingloader demonstrated the efficienthard machining of a drive shaft. Theworkpiece was pre-manufacturedand hardened using a MAXXTURN65 and then automatically loadedinto the E45 using the EMCO swingloader, hard turned, and unloadedusing the parts catcher.

A drive shaft measuring ø 250 x 1400 mm was manufactured using theMAXXTURN 110. The boring, milling, and geartooth milling operations neededto do this highlighted the versatility of the machine.

[The EMCOnomist ] Events

[EMCO technology day]Exciting insights and promising prospects at the Halleinexhibition center.As part of its technology day on 26June, EMCO provided exclusive infor-mation about the upcoming innovationsthat were presented at the globalindustry event, EMO, in Milan inautumn.The visitors first received an exclusiveintroduction to the new products(HYPERTURN 45, MAXXMILL 500,EMCOMAT E-200, EMCOMAT FB-450 Land FB-600 L) and had the oppor–tunity to discuss the latest trends in the

world of machining with research anddevelopment managers. Fascinatingmachining examples from the powerengineering medical technology, drivetechnology and automation sectorshighlighted the versatility of the EMCOmachines. Interesting presentations ongear tooth milling, automation, andprogramming using Esprit gave thevisitors a closer look at the productsolutions and the technology behindthem.

Many customers took up the invitationto contact EMCO directly for moreinformation prior to the EMO.

Selection of the machining examples shown

The economic crisis loomed large,not even sparing the EMO. Big-namemanufacturers withdrew their regi-strations. Fear began to spread thatthe EMO, the most importantEuropean industry event, could turninto a regional trade fair. But justbefore the event itself, reports showedsigns of newly increasing optimism.

EMO despite the economic and finan-cial crisis: 1,300 exhibitors (EMOMilan 2003: 1,648) presenting on anarea measuring 100,000 squaremeters (2003: 127,275) and 124,660visitors (2003: 155,364) were re-gistered. Taking into account thedecline in production of up to 70 %across the machine tools industryand cost-cutting measures in allareas, the figures for this year’s EMOare remarkable.The facts proved the fears that theEMO would only receive regionalItalian interest to be entirely unfoun-ded: 41 % of visitors to the event hadcome from abroad. This was anincrease of 2.5 % in comparison withthe EMO held in Milan in 2003. Themajority of visitors came fromGermany (12.8 %), the USA, theCzech Republic, Finland, France,Japan, India, Poland, Russia, andSwitzerland. It was also interesting tonote that 40 % of the foreign visitorshad come from countries outsideEurope. Even the range of exhibitorshighlighted the international charac-ter of the event. Almost 20 % of theforeign visitors were from Asia. In

total, companies from 39 differentcountries came to exhibit.Pier Luigi Streparava, GeneralCommissioner of the EMO Milano2009 and an employee of the eventorganizer, CECIMO, expressed hissatisfaction: „These figures emphasizehow important this event is, despite thedifficult economic climate, and haveconfirmed that it is an event able toattract a wide international public.“EMCO echoed this positive impression.„The visitors and exhibitors wereindeed a very international crowd,“said sales director Walter Voit. Initialdoubts that the EMO in Milan wouldbe able to achieve the success ofprevious EMO events were dispelledfrom the very first day. Numerous visi-tors showed interest in EMCO’srange of products. The new productson show attracted the most attention,in particular the HYPERTURN 45, a

highly productive turning and millingcenter for the complete machining ofworkpieces in mostly unmanned pro-cesses, the MAXXMILL 500, a verticalmilling center which can machine fivesides of a part in just one clampingcycle, and the EMCOMILL E350, themilling machine for standard 3-axismilled part production. However,even the established productionsolutions such as the MMV (floor-typemilling center) were well received.„Considering the current economicsituation, we should be extremelypleased with this year’s event. Wesold a few machines and made ex-tremely promising contacts. A slightimprovement in demand is becomingnoticeable. Whether this proves to besustainable remains to be seen,“ saidVoit.

Christoph Wernz, Head of R&D for the EMCO Group, on impressions of the EMO:

Nothing groundbreaking was presented at the EMO. The hype surrounding linear motors, hexapods, and robot solutions isover. These technologies are held back by their lack of cost-effectiveness. For me, the Sinumerik 828 is a promising examplefor new developments with a promising future. The new control from Siemens proves to be very important to our customers.It is ideal for the job shopper and we are proud that we have developed the first European machine to include this control inits programming. The customers responded very well to this, which is an incentive for us to offer this control in other EMCOmachines.

[5]

Events [The EMCOnomist ]

[EMO 2009]Surprisingly positive and international

[The EMCOnomist ] Case study

[6]

“A pump is a device used to movefluids, such as gases, liquids or slur-ries. A pump displaces volume byphysical or mechanical action. Theydisplace fluid, causing a flow.“ This iswhat Wikipedia tells you. If you consi-der this concept, you will see howmany uses pumps have in our every-day lives – almost without us evennoticing: from the simple bike pumpto (waste) water pumps and heatingpumps in households, through topumps that connect the electronicsand mechanics in your automobileengine. Pumps are as essential in private hou-seholds as in industry. GRUNDFOS,the world’s largest pump manufactureraccording to the German EngineeringFederation (VDMA), produces morethan 30,000 pumps every day for buil-ding services engineering alone,thereby demonstrating their wide rangeof uses and high level of diversity.

Grundfos – the world’s largest pump manufacturer

Grundfos supplies the global marketwith 16 million pumps every year. Tooperate in such capacities, it requiresmachinery that is both highly produc-tive and reliable. This is where thecompany from Bjerringbro in Denmark

turns to its partner of many years – inline with the saying “you know whenyou’ve found a good thing”; Grundfoshas placed regular orders with EMCOsince 2001.To enable it to efficiently produceparts for connecting the electronicswith the mechanics in the pumps,Grundfos laid down a new challengefor EMCO in October 2008. Its specifi-cations were clear: Pre-pressedNirosta parts needed to be machinedby an automatic CNC universal tur-ning machine. The machine should beas compact as possible, have extreme-ly flexible usage options, offer greatvalue for money, and enable largelyunmanned production.

Automatic production of pump components using the EMCOMAXXTURN 45

Under precise consideration ofGrundfos’s requirements, EMCOdeveloped a MAXXTURN 45, equip-ped with a swing loader, main spindle,tailstock, tool turret incl. driven tools,parts ejector, part catcher and a partaccumulating conveyor. With thissolution, connection elements can belargely manufactured automaticallyand without human involvement: Theswing loader takes less than 5

seconds to automatically load themachine with the pre-pressed parts. Achuck that is specially tailored to thedimension of the raw parts is moun-ted to the main spindle with a spindlebore of 45 mm, making it possible tomachine the parts without lengthyconversion. The main spindle’s posi-tion in large precision bearings facilita-tes the especially large speed range(0-6300 rpm) and an exceptional running truth. The cooling fins on thesymmetrically designed headstockprovide excellent thermostability. Thetailstock gives the workpiece extrastability during the machining pro-cess. It is attached to the roller slideand can be automatically positionedwithin a range of 510 mm. The toolsand the swivel movement of the 12-position VDI 25 radial turret arepowered by a servo motor. The partsejector transports the completedworkpiece onto the part catcher. Thepart catcher places the connectionelement on the parts conveyor.The loading and unloading systemenables Grundfos to largely automatethe manufacturing process. The lowlevel of conversion work enablesmachine downtime to be kept to aminimum. This leads to excellent pro-ductivity and high workpiece profitmargins. 50,000 pieces can be easily

[Everything’s flowing nicely]The diverse uses of pumps

manufactured per batch. The automa-tion also saves on personnel costs:The machine lead time for this partsrange is approximately 65 minutes.“An excellent time, especially whenconsidering how small the machine’sfootprint is”, according to HelmutHuber, Head of Technical SupportGermany at EMCO. The MAXXTURN 45 can be flexiblyupgraded and can therefore be usedfor diverse machining requirementsand parts ranges.

“Extremely non-bureaucratic andhighly productive”, that’s how HelmutHuber, at EMCO, describes the long-term cooperation with Grundfos.”

Grundfos has a clearly defined pro-cedure for procuring a new machine:The procurement department recei-ves proposals from several manu-facturers, selects three of these andpasses them on to the productiontechnician department and themachine operators. After all, that’swho makes the decision. JesperKnudsen, production engineer atGrundfos, explains, “After all, ourproduction department has to usethe machines on a daily basis. Weselected EMCO because we havebeen successfully working withEMCO for many years. Reliability,precision, productivity, and profitabi-lity are extremely important criteria

for us. And so far, EMCO machineshave always fulfilled these criteria.”EMCO’s service is another factor inthe decision. “Our engineers andmachine operators have receivedEMCO service training and are the-refore able to independently carryout minor repairs.” If more seriousproblems ever arise, the EMCO cus-tomer service team guarantees aresponse within 24 hours.

“Extremely non-bureaucratic andhighly productive”, that’s howHelmut Huber, at EMCO, describesthe long-term cooperation withGrundfos. Huber supports the globalplayer in all its technical needs andworks with the Grundfos productiontechnicians to develop machinesthat meet Grundfos’s individual pro-duction requirements. “You can tellthat the professionals are at work atGrundfos.” Grundfos has extremelyhigh vertical integration: In additionto pumps, the Danish companymanufactures engines and sensorsand even spent a while manufactu-ring machine tools. Its expertise isequally as broad. This means that Grundfos also hasthe expertise to evaluate the produc-tivity and quality of EMCO machines:“We have been using theMAXXTURN 45 since December2008. The highly productive loadingand unloading system has reducedthe machining time by 50% com-pared with usual machines, andenables us to increase the pieceprofit margins by 65%, due to a 3station machine system instead ofthe old single machine.“ This has certainly played a part inkeeping everything ‘flowing nicely’at Grundfos.

The cooperation between EMCO andGrundfos is now on a multilateralbasis: Grundfos is both an EMCOcustomer and an EMCO supplier.EMCO machines are used to producepump parts while the coolant for theturning and milling machines flowsthrough Grundfos pipes.

Pump solutions [Be > Think > Innovate]

Its original meaning of ‘flowing up out of the ground’ is clearly apt for Grundfos: In 2008, the Danish company and its 18,236 employeesaround the world generated a turnover of EUR 2.6 billion and is the world’s largest manufacturer of liquid pumps according to theVDMA. With more than 80 sales and service branches in 45 countries and production sites in Europe, Asia and North and SouthAmerica, Grundfos is a global player and supplies the global market with around 16 million pumps every year. Grundfos’s target areasinclude fitting private, communal and industrial buildings with heating systems, air conditioning and sanitation facilities; cleaning and(waste) water management; automotive and machine tool supplies and water purification for the food industry.True to its slogan of ‘Be > Think > Innovate‘, Grundfos invests 5% of its annual turnover in research and development and places agreat deal of value on high vertical integration. The engines, sensors, and many parts of the pumps are manufactured in house.

Case study [The EMCOnomist ]

[7]

Reliability, precision, pro-ductivity, and profitabilityare extremely important criteria for us. And so far,EMCO machines have always fulfilled these criteria.

,

Jesper Knudsen

[8]

Three young Blum employees participated this year at the 40thWorldSkills International in Calgary, Canada. They had quali-fied for this major professional event – which takes place onceevery two years – through their previous victory at the Austri-an championships. As usual, the CNC turning pre-selectionswere hosted once again this year by EMCO Maier, in Hallein,Salzburg. With their speed and competitive spirit, the young com-petitors gave the EMCO machines in the exhibition center a goodworkout. Benjamin Poredos from Blum won out against his con-temporaries from Swarovski and W&H and secured his ticketo the finals in Calgary. And the trip was worthwhile: Alreadyaccustomed to success, the hardware manufacturer Blum inHöchst (Austria) once again added to its 22 strong medal

collection: Benjamin Poredos received a gold medal in the CNC-turning category and also secured the national victory, winninghim a second gold. A silver medal was won by another Blumapprentice in the polytechnics category.This year’s championship clearly shows that the best professionals from around the world were neck and neck intheir performances. Particularly when it comes to technicalprofessions, it is often thousandths of a millimeter thatdetermine who wins a medal, so good training and thoroughchampionship preparation play a vital role.

[Gold and silver]Gold and silver medals for Blumapprentices at the professional world championships 2009 in Canada

The successful Blum apprentices (from left to right): Benjamin Poredos (gold), Lukas Winkler (5.) and Benjamin Grabherr (silver)

„Quality, not quantity“ was the aim EMCO – being the worldmarket leader with an experience of 25 years of industrialtraining – had, when developing the concept of the EMCOcompetence centers. Priority was given to setting up teachingand training centers clustered in Central Europe equippedwith state-of-the-art technology and creating a pleasant andrealistic environment for industrial training. And so the requi-rements for future EMCO training centers were defined. Onlycenters which meet the following requirements can becomepartners:

- The training centers must be equipped with EMCO machines,- Trainers must receive in-depth, ongoing training on the

machines.- The premises, machines, workpieces, and multimedia

training materials adapted for the training courses mustbe available in order to provide high-quality training forjobs in the metal machining industry.

The regional popularity and acceptance of the training centersand institutions should be connected with the industrial know-

how of the supplier EMCO in a well-balanced measure. Thatway, an advantageous partnership for both sides is generatedby which primarily the apprentice should benefit from. During the planning and implementation stages, EMCOsupports and advises its partners with the help of planningand interior design experts.Furthermore, the EMCO training centers are serviced and sup-ported by means of an all-inclusive package which includesongoing maintenance, updates training, tool starter packages,special software offers at introductory prices, and much more.‘From the industry, for the industry’ – as a complete serviceprovider, EMCO is aware of the market demand for industry-oriented training and knows what is required of specialiststaff in industrial enterprises. It meets this demand with aselective choice of Centers of Excellence designed to deli-ver high-quality industrial training.

Do you wish for more information about the EMCO Centersof Excellence? In order to have the chance to inform you per-sonally about all the details, please call +43(0) 6245 891-291,or write us a mail: excellence@emco.at

An investment in knowledge stillyields the best returns[ ]Benjamin Franklin

Industrial Training [The EMCOnomist ]

Even in difficult economic times, training and development foryoung adults, jobseekers, and even further vocational trainingis becoming more and more important. Since it was foundedin 1992, the Elbe vocational training center has been dedica-ted to continuously developing metal, wood, retail, storage,construction, painting, and secretarial courses.The commissioning of several new training courses by theEmployment Office in Wittenburg made it necessary to createcourses in CNC programming and CNC metal machining inspring 2009. After the bids were examined in detail, EMCO wonthe contract thanks to its training machines, the ConceptTURN 250 and Concept MILL 250, and its unique sellingpoint: interchangeable control. As well as the industry stan-dard of the machines and their excellent value for money,

the recommendations of existing EMCO training customershelped Thomas Glück, the Managing Director of Elbe Voca-tional Training Center Elbe GmbH, to make his decision.

The Austrian company Swarovski is the world’s leadingproducer of multi-faceted crystal. Daniel Swarovski, thecompany’s founder, whose motto was „constantly improvingwhat is good“, set his successors and employees cleargoals in 1895: constantly developing, learning, and improving,and never being satisfied with what is average: in all areasof their work. The company’s huge success has proved itsfounder right.This spirit is also to be found in Swarovski’s training work-shops. Here, students are taught the satisfaction to be foundin learning and development. Of course, manual skills and allthe associated skills must be perfected first. The Swarovski

trainers teach their students this constantly and under watch-ful supervision in the company’s own training workshops,which are equipped with numerous EMCO machines. Bothtraining machines and conventional EMCO machines areused there on a permanent basis.Long-standing co-operation in a partnership and the reliabi-lity of EMCO contacts and machines mean more to Swarovskithan short-term special offers. EMCO works hard to live up to Daniel Swarovski’s motto in its cooperation with Swarovski, because only suppliers with similarly strictstandards for their own services and products will be ableto work together with Swarovski in the long term.

[Constantly improving what is good]50 years of Swarovski training workshops

Quote: „Since 1959, 1,100 young peoplehave begun their careers in our trainingworkshops. We intend to continue develo-ping and promoting this system in future,because the future of Swarovski dependsheavily on the skills of its employees. Forthis, we need well-equipped training work-shops and industry-standard machines.“

Manager of the “metaltraining” team, MichaelBrett, and student Matthias Schneider.„It’s fun teaching youngpeople about thesemachines“.

Johann Hintner,head of machineshops/servicedepartments

Image: Elbe vocational training center

[9]

Training and development at the Elbe vocational training center[ ]

Increased productivity, reduced ancil-lary times, maximum machine utilizati-on, complete machining, low-manpo-wer manufacturing ... all of these arecurrently hot topics in the relevantspecialist literature.All the factors that influence manufac-turing conditions are coming underever closer scrutiny and are beingassessed to determine their potentialfor optimization.One common goal unites all of theseprocesses: cost minimization. Thisincludes reducing set-up times, ancil-lary times, and operating times, as wellas preventing downtime and mainten-ance time, and reducing personnelcosts through multiple machine opera-tion. EMCO provides the solution withits modular range of machines andaccessories that can be individuallyconfigured by the customer, a solutionbased on EMCO’s high level of techno-logical and machining expertise. EMCOworks with the customer to analyze itsmanufacturing requirements and deter-mine the best = most efficient solution.Of course, this commitment to efficien-cy also takes into account processreliability and quality.One key factor for minimizing costs iscomplete machining – an often usedterm. But what exactly does this mean?

Gerhard Meisl, Senior Product Managerat EMCO, provides the following expla-nation: „Complete machining refers tothe manufacturing of a component injust one operation, mostly involvingtwo clamping cycles within the machinetool. This prevents the need for addi-tional clamping cycles, follow-on operations, and the associated waittimes. However, it is also dependent onthe tool complexity and associatedrequirements, level of precision, surfacequality, and machining volumes.“EMCO supplies turning and turning/mil-ling centers that use driven tools, a Caxis, and counter spindle to manufac-ture workpieces in one operation.Whether complex parts that requireextensive milling or more simple turning workpieces – EMCO has a cus-tomer-specific machine configurationand automation components for everyrequirement. After all, without clever,cost-efficient automation, completemachining is only half the solution andhas little to offer for the future.The wide range of EMCO automationcomponents enable the machines to beconfigured to create customer-specific,fully automated manufacturing cells.When devising system solutions,experts from EMCO’s Automation divi-sion are involved in the development

process from the outset: whether for barstock or preprocessed blanks – theEMCO automation portfolio has thesolution for any requirement. For ex-ample, optimized bar loaders are avai-lable for all machines: the EMCO swingloader for the 45 machine range and theEMCO gantry loader for sizes 65 and95. The finished parts can be unloa-ded using the basic parts catcher or, forlonger, wavelike parts, the counterspindle. Robot solutions can also beused to combine machines into manu-facturing cells for fully automated pro-cessing.

The systems implemented for the medi-cal technology and transportation indus-tries provide just two examples of cus-tomer-specific system solutions. Aswith all industrial sectors, the key focushere is on providing reliable proces-ses and reducing the number of opera-tions required, as well as on ensuringa continuously high level of quality andprofitability during manufacturing.

[Turn-key solutions]EMCO as an integratedsystem supplier

[10]

[The EMCOnomist ]

Great performance within a small space. The new EMCOMILL E350.

Compact, powerful and flexible. The EMCOMILL E350 andthe training machine Concept MILL 250.The new vertical CNC machining center EMCOMILL E350with a travel in X of 350 mm convinces with its small foot print,its flexible applicabilities and its very attractive price-perfor-mance ratio.The EMCOMILL E350 is especially applicable for the produc-tion of small parts in small and medium lot sizes. Small partsup to a size of 350 x 250 x 300 mm can be machined quicklyand precisely.

Save time, money and space with theMAXXMILL 500!

EMCO customers can now enjoy a new, flexible vertical CNCmilling machine for 5-sided machining in the form of theMAXXMILL 500. In just one operation, complex workpieces withan edge length of 500 x 500 x 500 mm can be efficiently andprecisely machined. The compact machine structure andexcellent value for money also enable customers to make furt-her advantageous savings.

Highly productive, highly dynamic! The new HYPERTURN 45.

On taking a closer look at the machine and its components,insiders would notice that the new HYPERTURN 45 has seve-ral aspects in common with the EMCOTURN 332. Well spot-ted! The machine is in fact based on the EMCOTURN 332. The new HYPERTURN 45 is distinguished by even greaterdynamics and technical sophistication, and therefore impres-ses users with the additional options for machining workpie-ces and increasing productivity.

High power universally applicable. The EMCOMAT E-200 with EASY CYCLE.

With the EMCOMAT E-200 EMCO expands its very success-ful EMCOMAT lathes series. The new machine satisfies thedemand of cycle-controlled lathes with a height of 200 mmabove centers centers and a distance of 1000 mm betweencenters. The EASY CYCLE, the powerful teach-in control, thehigh machining performance, the solid heavy construction,the utmost precision and the universal applicability as wellas the optimal price-performance ratio are the highlights ofthe EMCOMAT E-200.

[The EMCOnomist ] Novelties

[12]

[New]

For the industry:EMCOMILL E350

For training:Concept MILL 250

Editor: EMCO MAIER Ges.m.b.H.Salzburger Str. 80 . 5400 Hallein-Taxach . Austria

Editor in chief:Christa Vergnes, EMCO Group . E-Mail: info@emco.at www.emco-world.com

usa

italy headquarters

germany

czech republic

italy

[Engineering from the Heart of Europe]

LINEARMILL 600 HD: consistent cutting forces for perfect surfaces

Hip implants are constructed in part fromplastic, ceramic, or steel alloys and eachmaterial places specific requirementsupon the machine. If the parts are madeof highly alloyed steel or titanium, the pri-mary considerations are stability andpower. For plastic workpieces, attention

must be paid to chip removal and, inparticular, careful clamping of the parts.Medical parts made out of ceramic aremachined when soft, a process referredto as green machining. The machiningprocess does not result in chips as such;it only produces dust. The dust producedis highly abrasive and is damaging toall machine tools. Working with therespective preventive measures canextend the durability of the machinessignificantly. Another challenge with thesefragile parts is the clamping technologyused. The specialists at EMCO Automa-

tion have developed machine modifica-tions and accessories for precisely theseapplications.Machines including the MAXXTURNseries - MAXXTURN 45 and 65 - and theEMCOTURN 332 and EMCOTURN 420equipped with process-specific solutionsand adaptations have been success-fully deployed in the medical technologysector over recent years.

Airplanes, ships, trucks, and trains pro-vide maximum mobility and ensure therapid availability of goods. Whethership propellers, structural componentsor pulley wheels for elevators - thesignificance of mobility and the asso-ciated increase in production quantitiesrequire intelligent manufacturing pro-cesses. Ship propeller manufacturingpresents a particular challenge as itinvolves the precise machining of com-plex profile surfaces set at angles toone another. Even minor differencesin form or slightly exceeding the tole-rances for surface quality can resultin a loss of efficiency of up to 10%.Achieving the predefined geometriesand surface qualities requires the cle-ver use of clamping in the millingmachine in order to prevent the blades

from swinging out, as well as an opti-mal machining strategy for multi-passmilling. Five axis simultaneous millinghas decisive benefits in this case. Itenables optimal tool engagement whilemaintaining a continuous angle. Thisproduces consistent cutting forces,resulting in perfect surfaces. TheEMCO LINEARMILL 600 HD with line-ar drives in the X/Y/Z axes and directdrives in both rotation axes is ideallysuited to this task.

No matter how complex and difficult themanufacturing requirements may be, itis still possible to apply intelligent com-plete machining and system solutions.After all, this is „just“ a matter of machi-nes and development expertise. Howe-ver, ensuring that the solutions are suc-

cessful when used for day-to-daymanufacturing depends largely on theassociated implementation process.One thing must always be kept in mind:the more complex the machines andmachining processes, the higher thedemands made of the operators. Theyneed to be skilled multi-taskers who areexperts in all manufacturing techni-ques and are willing to learn new thingsevery day.Emco therefore offers its customers and their manufacturing teams compre-hensive process support, training, andadvice to ensure that manufacturinggets off to a successful start - rightthrough to the completion of the firstmanufacturing batch.

[The EMCOnomist ]

[Medical technology]

[Transport] [11]

The EMCOTURN E25 can be used to manufacture medical products such as hipjoint inlays cost effectively and with a high level of precision.

• Powerful, smooth inline milling spindle with direct drive (10,000 rpm, 7 kW, 41 Nm)• High feed rate in the linear axes• 20-tool magazine with a fast two-arm changer for short tool changing times• Linear guideways free of play providing high precision and dynamics• Numerous options ensuring high flexibility• Combined with EMCO ROBO LOAD for automated loading of single loads productivity is increased• Cutting-edge control technology with the new Sinumerik 828, respectively with the established

interchangeable control for industrial training

• Maximum stability and thermosymmetry• Short power flows ensuring optimum precision and outstanding surface qualities at the workpiece• Screw conveyor for chip removal• Tool magazine with 30 tool stations• Mechanic spindle

• Powerful main and counter spindle• Two tool systems with up to 24 driven tools• Stable Y axis• Water-cooled spindle motors• Dynamic digital drives• Thermosymmetric machine construction• Compact dimensions

• High chip cutting power• Solid gray-cast construction of the machine bed with strong ribbings for a vibration-free machining• Fully automatic central lubrication of X and Z guides and of the ball screw spindles• Electronic handwheels for X and Z axis for manual operation• EMCO Easy Cycle control with 3 operation modes: manual, teach-in and program mode

[Highlights]

Dental angle piece (HT 45)

Housing (MM 500)

Flange (E-200)

Cutter head (CM 250 and E350)

Novelties [The EMCOnomist ]

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