Among providers of sophisticated machine tools and manufacturing systems, the FFG brands are characterized by a wide range of technologies and application know-how. Manufacturers like VDF Boehringer, Tacchella, Pfiffner, HESSAPP, Modul and MAG have been pioneers in the fields of milling, turning, grinding and gears. They have developed into specialists in turnkey systems, flexible manufacturing cells, rotary transfer machines and the complete machining of large, complex parts. As a group, these manufacturers can present this proposition, references and new developments to the specialist audience at leading trade fairs such as AMB. "We are looking forward to welcoming our customer base to our home region of Stuttgart and demonstrating many new opportunities to them. The experts in all our plants have focused their innovation work on the AMB and they have achieved inspiring results. Product premieres from Modul, HESSAPP and Tacchella, the demo cell from our MAG factory automation team and the different technology and software premieres are just a few examples", states Dr. Gerald Weber, CEO of FFG Europe & Americas.

The opportunities of networked manufacturing

The breadth of the FFG portfolio will offer trade visitors to the AMB a global understanding of the latest developments in modern manufacturing. A spherical design, the "iGlobe", is the focal point of the exhibition stand and symbolizes FFG's holistic approach to production. This is where the group's portfolio of machines, application development and digital services will be clearly displayed, enabling an intuitive understanding of the opportunities of networked manufacturing. Around the "iGlobe" the FFG brands will be presenting their highlight applications in the areas of automobile powertrains, e-mobility, aerospace, rolling stock, retrofitting and volume production for various sectors.

Technology, machines and automation from a single source

MAG is an established system provider at FFG; in particular it deploys its system competence and experience to develop new and flexible automation concepts. At AMB the MAG factory automation team is presenting a machining cell offering maximum flexibility. A MAG SPECHT 600 machining center with pallet changer is at the heart of the setup. A portal robot is used for loading parts or even tools into the machine or pallet changer. These are provided by a driverless automatic guided vehicle (AGV), which can usually be equipped with many different kinds of workpiece carrier and robot interface. Part handling is operated via a vision system and the entire cell is controlled by a central CNC, which in turn is connected to an industrial cloud application.

Turbochargers: modular solutions for all components and quantities

A further automated cell at the exhibition booth is aimed at turbocharger manufacturers. The FFG portfolio offers the opportunity to intelligently combine our technologies providing high productivity, precision and flexibility – in terms of optimizing your part costs. FFG will be exhibiting a live example at the AMB in the form of a robot-automated cell with a MAG SPECHT 450 DUO double-spindle machining center and a Leadwell TW-8 double-spindle turning center. The DUO can be equipped for an annual throughput of 200,000 to 500,000 turbocharger bearing housings at moderate investment costs. Bearing housings made of gray cast iron GGG250 will be machined at the trade show at a cycle time of 90 seconds per part. In addition to this live application, FFG will also use rotary transfer and grinding machines to present its solutions for compressor and turbine housings, bearings and turbine shafts.

Pfiffner – twelve precise parts per minute

The Pfiffner experts, together with their rotary indexing colleagues from IMAS and Witzig & Frank, have specialized in the sequential complete machining of large quantities and thereby exploit a variety of technologies. The Pfiffner exhibit at AMB will demonstrate a real customer process on its HC 32-16 Hydromat hydraulic rotary transfer machine, equipped with modular CNC machining units. The latest control technology and full CNC control of up to 5 axes per station ensure the shortest cycle times and highest yield rates at consistently high quality. This machine performs the complete off-the-shelf machining of an airbag holder in 5.1 seconds.

Full gear manufacture on HESSAPP and Modul machines

Modul, HESSAPP and VDF Boehringer have been working for many years in the field of integrated turning and gear manufacturing. The Modul technology portfolio recently grew with the acquisition of MHD, a company in Chemnitz with a similar technological and historical background. This adds bevel gear machining and stamping to its range of processes for the soft machining of gears. This brand also developed its own solution for skiving, including a comprehensive software package. These additions complete the FFG offering in terms of the soft machining of gears, together with the existing solutions for hobbing external and internal gearing, cold forming, chamfering and deburring.

The Modul exhibit at AMB will be its B 320 bevel gear manufacturing machine for applications up to 350 mm. An innovative machine and drive concept enables high-performance machining of straight bevel gears. CNC-based tool replacement, main axes directly driven by torque motors, absolute measuring systems in all axes and a central, generously designed chip removal concept all permit productive applications, for example in agricultural equipment, conveyor systems or general engineering. Right next to this premiere, HESSAPP is exhibiting the new skiving process that has already been implemented in a customer's machine. A real customer workpiece will be machined on the DVH 500 L WS, involving internal skiving, external facing, longitudinal turning and the milling of a decentralized pocket on the inside of a spur gear. These proven machine concepts therefore provide another extension to the technology range used in various applications, such as the heavy goods vehicle, e-mobility or agricultural machinery sectors. Special software packages for skiving and bevel gear machining round off this double gear manufacturing demo. They can be tried and tested live on the machines.

All-purpose solution for flexible large part machining

The renowned manufacturer VDF Boehringer will be celebrating its 175-year anniversary next year. Its unique success story in turning and crankshaft machining will be represented at the AMB by the VDF 1300 DUS, a cycle-controlled turning center with extremely high cutting performance. Cycle-control and the option for manual operation mean that turning centers in the VDF DUS series are mainly used in small series and single-item production. An automatic turret and a second chip protection door enable full CNC operation, and thereby extension of its economic use also for medium-sized series as an alternative to a CNC lathe.

Leadwell BC 600 – universal 5-axis machining

Leadwell is a sister-brand in the FFG Group and offers creative solutions for machining complex workpieces with a large configuration width. The BC-series is equipped with a torque-driven C-axis rotary table and a swivel head meeting all the requirements for flexibility in use. The available Heidenhain or Siemens controls also enable simultaneous 5-axis and 5-sided machining, resulting in shorter processing times and higher performance.

Tacchella Crossflex – the grinding experts from Cassine in Italy present an external cylindrical grinding machine with in-process measurement and flexible automation options.

The UNIMOG – a true Boehringer! The Unimog 70200 was the first series-produced vehicle in the Unimog range, which was then produced under the batch name "Ochsenkopf". Exactly 600 of these vehicles were manufactured at Boehringer in Göppingen between June 1948 and April 1951, before their production was sold to Daimler-Benz. Around 100 to 120 examples still exist, one of which can be seen at the FFG exhibition booth at the AMB on the occasion of Boehringer's upcoming 175-year anniversary.