'The show' transforms Chicago into first city of manufacturing.

The International Manufacturing Technology Show is the Appian Way of metalworking manufacturing, a biennial crossroad that showcases innovation and innovators from around the world. IMTS 2006 proved no exception--as more than 85,000 people swelled the cavernous halls of Chicago's McCormick Place last month to seek out the tools and the techniques to compete in the global manufacturing market.

The 26th edition of North America's largest manufacturing and technology show boasted more than 1,200 exhibiting companies taking up 1,150,000 sq ft of exhibit space. And more than 80 nations were represented at the show owned and managed by AMT--The Association For Manufacturing Technology.

Reflecting its 20th century roots as a good old "machine tool show," IMTS 2006 was a lively venue of buying and selling, teams weighing the values of upgrading production floor equipment, and manufacturing professionals sharing new ideas and engaging in "curbside consultations."

At the same time, IMTS proved to be much more than an occasion of commerce. The Emerging Technology Center (ETC) allowed attendees to learn about initiatives and research taking place in the manufacturing community, AMT notes that this year's ETC theme, Any Size--Any Time--Any Where, has been "a topic at the forefront of the international playing field where industrialists continue to track new approaches to producing goods of high quality, at a low cost, and in a short time to compete for business worldwide."

"We need to understand these advanced chapters to provide a competitive edge in the international marketplace," said Peter Eelman, Vice President--Exhibitions. "The center gave visitors a significant leap in planning ahead wisely to integrate these new processes not too far down the pipeline."

Similarly, the Student Summit continued its mission to lay the proper groundwork for the next generation of manufactures by bringing together educators, students, and exhibitors to share the wonders of state-of-the-art metalcutting, metalforming, and production strategies.

Even the fun of BattleBots IQ reminded IMTS visitors that the imagination continues to power advancements in metalworking manufacturing.

Long before the doors of IMTS 2006 actually opened, AMT President John B. Byrd III pointed out that U.S. value-added manufacturing output is at record levels. "Manufacturing is in a time of transition and that process has been accelerating for three consecutive years," he explained. "What has changed is that manufacturing employment has fallen some 20 percent over the last two decades. The reason for this is the tremendous, continuing rise in productivity, allowing fewer workers to produce more goods, faster, and at lower cost." Underpinning that productivity, Byrd said, is innovation and technological advancements.

As many visitors to the Chicago show agreed, innovation and advancement were certainly the main attractions at IMTS 2006.

Changing landscape

The sharp-eyed at IMTS 2006 particularly observed that the manufacturing landscape had sustained notable shifts and subtle but significant transformations from a general business perspective. Certainly the most noteworthy was the presence of MAG Industrial Automation Systems--a group of leading machine tool and systems companies with a large portfolio of highly recognized and well-respected brands, including Fadal, Cincinnati Machine, and the now fused Cross Huller Ex-Cell-O Lamb.

As usual, Iscar Metals Ltd. was busy promoting the latest advancements in cutting tools, but it was doing so with the added cache of having Warren Buffett's Berkshire-Hathaway investment firm as its new majority owner.

The Iscar deal, completed last spring, reflects the formula for manufacturing success in the 21st century, as T&P columnist Mark Stover noted. (See "Warren Buffett is big on metalworking," July 2006.) '"Perhaps we can all smile that our often-overlooked industry has caught the eye of someone like Warren Buffet," observed Stover. "And it may not hurt to keep in mind that Iscar is a living example of a company that found great success and growth by staking out successful niches and embracing globalization."

Serious horsepower

As soon as the post-Labor Day show began, attendees gravitated toward the "big machines." After all, when you're under the big top, you want to get as close to the lions as possible.

Tornos Technologies brought its new DECO 20s Swiss-type machine to Chicagoland. The machine is targeted to medical, automotive, electronics, connector, and general manufacturing companies producing precision parts that are moderately complex and up to 20 mm in diameter. According to the company, the DECO 20s is a "mirror image" machine, having almost an equal number of tools available for both the main and counter spindle. Both tool systems have three fully independent axes, for a total of six axes. The company also refers to this versatile and flexible model as "two lathes in one."

"The DECO 20s addresses a need in the marketplace for a versatile Swiss-type machine that sets up and produces parts quickly, and that also won't break the bank," said Mark Saalmuller, Tornos' marketing and communications manager.

The folks from Daewoo-Doosan displayed their DMV 3016L vertical machining center with its massive, one-piece bed with box-type column--a guarantee of stability during rigorous cutting. Of note is the 40-taper, cartridge-type spindle powered by a 20hp (15min) spindle motor. Power is transferred through a cogged drive belt, eliminating slippage and vibration while promoting thermal stability. An encoder attached to the spindle enables synchronized high-speed rigid tapping with a standard collet chuck. Tapping depths are accurately controlled and the need for special tap holders is eliminated.

Chiron America Inc. showcased its latest machine tool technology, including two CNC milling machines featuring barfeeders. The company's Mill 800 Vertical Machining Center was demonstrated with several new productivity enhancers, and the FZ08KS Tilt VMC was shown making parts from bar.

"It's an interesting and unique concept," explained Glyn Williams, engineering manager for Chiton America. "These are bonafide milling machines, not turning machines, and the barfeed permits high productivity, with little operator intervention, and ideal for 'lights out' operation."

"The other thoroughbred from Kentucky," Mazak Corp. took advantage of its new location at IMTS, the premier front-row position. From that venue, it showed the new Nexus QTN 450M, a powerful, high-torque multitasking CNC turning center featuring a large-bore spindle. With a maximum swing of 33.3" and maximum machining diameter of 22.8", production versatility and productivity for larger-diameter workpieces is ensured with the combination of a 40hp turning spindle with 1,327ft-lbs of torque and a 12-station turret with a 10hp, 4000-rpm milling spindle (2000rpm optional). Maximum speed on the integrated spindle/motor unit is 2000rpm and the spindle bore is 6.5", the greatest capacity in its class. Feeds are 1181 ipm in X and Z axes.

Technology took the spotlight along with big machines this year. Case in point: Charmilles' ROBOFIL 240cc demonstrated the benefits of the recently unveiled Turn while Burn technology. This unique innovation combines a servo-controlled B-axis with wire cutting in the X and Y axes to provide increased functionality. Turn while Burn can be added to any cc model of wire EDM and allows for the machining of highly complex 3-D components, the company said.

MC Machinery Systems Inc. used IMTS to emphasize the importance of the medical manufacturing market. The booth's medical area featured an automated cell simulating the use of waterjet and wire EDM technology in the production parts process. Equipment demonstrated included the MD+Cell Wire EDM with Mitsubishi Robot and Waterjet Suprema four-axis Water jet.

The booth of Toyoda Machinery showcased the latest in machining technology, including a new line of vertical machining centers, horizontal machining centers, tool storage systems, and grinding technology. Its AF-Series of new vertical machining centers offers unsurpassed performance and value for high-speed machining applications. The direct-drive 12,000rpm, temperature-controlled spindle is paired with the powerful Fanuc 18i-MB control to meet the demands of complex die/mold applications.

Teamwork was on display as well. BIG Daishowa Seiki and BIG Kaiser Precision Tooling Inc. introduced Air Power Spindle to the market. Air Power Spindle provides solutions "to the endless challenges of micro-machining with ultra-high-speed and precision." Air Power Spindle offers maximum spindle speeds of 80,000rpm. Air Power Spindle is an air-driven tool that can be used on existing machining centers to provide dramatic enhancements to surface finish quality, extended tool life, and reduced wear on high-speed spindles. The new product minimizes thermal displacement in the Z-axis for top precision. When compared with a standard machining center spindle with up to 0.012mm of displacement, Air Power Spindle remains constant at less than 0.001 mm, the companies report.

Folks in the auto business got an eyeful when they visited the INDEX booth, which featured the new V160 vertical grinding and machining center. It incorporates ID/OD grinding, auto loading, and rough machining (hard turning) with automatic in-machine wheel dressing and in-process gaging, permitting the production of high-precision parts complete in a single chucking. According to Index, the new machine concept is based on input from potential users who looked for a way to combine turning and grinding in a single platform in order to reduce cycle times and improve part precision on a wide range of precision shafts, fuel-injector bodies, gears, and more.

Selling innovation

Every exhibitor at IMTS 2006 seemed to underpin his or her pitch with a common theme this tool can ensure accuracy, increase throughput, and deliver the goods" to the customer. In almost every case, this was no mere sales hype.

For example, Hardinge Inc. offered "a revolutionary concept" for large-part positioning, with its collet-ready A2-5 spindle at the heart of the indexing strategy. The same accuracy promised by the Hardinge lathe now extends to its large-capacity indexing/rotary table systems. A variety of standard 16C or 3J spindle tooling will mount directly in or on the high-precision spindle without the use of an adapter. Hardinge has added the 16C and 3J indexing/rotary table system to its successful 5C product, offering to provide rapid parts positioning as well as linear, arc, and spiral milling for different part sizes, shapes, and materials. Common spindle tooling can be shared from indexer to lathe. Collets, expanding collets, step chucks, and three-jaw power chucks will automatically center the part and afford superior grip force for heavy cutting.

Metronics Inc. showed off the QuadraChek 300, an advanced digital readout system that combines multiple video-measuring functions in a single display unit. Metronics proprietary technology combines video display, cross-line generator, and automated edge detection. "The QC300 represents a significant leap forward in video inspection" according to William Chambers, product specialist. "It is a powerful, cost-effective, easy-to-use readout solution that will reduce errors, speed inspection throughput, and greatly improve accuracy and repeatability."

According to Tim Fara, Kennametal Inc.'s global market segment manager for the machine-tool industry, such advances as a multistation tool that fits in a standard KM toolholder, yet indexes six positions like a mini-turret, proved of interest to manufacturers with lean and efficiency-building programs.

"This cuts tool-change time in multitasking applications and improves overall throughput time," Fara said. Multistation tools also save time and money by serving as backups for spare tools. "New multitasking machines are opportunities to look beyond increasing speeds and feeds and rethink an entire application or part-processing operation for achieving world-class productivity levels," Fara said. "Our goal is to enhance the machine tool and further optimize the performance."

At IMTS 2006, optimizing performance was a shared goal indeed.