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Optimised Tool Management Through Integrated Process Chain

Optimised Tool Management Through Integrated Process Chain

From the shrink fit chuck to the presetting device, aerospace supplier Heggemann relies on consistent Haimer quality in tool management. Article by Haimer.

Anyone who concentrates on the development and production of sophisticated metallic lightweight components and subassemblies is a predestined partner of the aerospace and automotive industry. And Heggemann AG is one such company. Since the company was founded in 1962, it has been supplying these two premium industries. But most of the orders come from the aerospace industry, for which Heggemann holds all the important certificates.

“We also undergo annual audits, not only by the German Federal Aviation Administration, but also by major manufacturers such as Airbus and Boeing, as well as first-tier suppliers such as MTU, Rolls Royce, and so on,” says Dr. Christian Howe, a member of the board at Heggemann. “Our slogan is ‘360°–From Engineering to Production’. Accordingly, we support our customers in all phases of the product development—from conception and development through simulation and engineering, to prototype construction, and the general and functional testing or the production of small series.”

The intelligent NG coil and integrated contact cooling make the Haimer Power Clamp Comfort NG shrinking machines very comfortable to work with help.

Machining at the Highest Quality Level

The highest quality standards apply at all times. This can be seen in production with state-of-the-art CNC milling and turning centres at the company. Ulrich Ahlers, head of machining at Heggemann, explains, “Here we cut a wide range of very demanding materials from titanium, Inconel, stainless steel, and steel, to high-strength aluminium. In most cases, it is the individual parts and small series that have a high demand for precision and quality. Accordingly, not only the machine shop floor, but also the tools and the tool management are of great importance.”

Ahlers and Juergen Ballbach, who is responsible for tool management, have taken on this field in order to optimise it. “Our desire was to achieve the greatest possible consistency in terms of the shrinking, balancing and presetting devices used. We succeeded in doing this together with our partner Haimer,” says Ahlers.

Ballbach has been using two Haimer Power Clamp Comfort NG shrinking machines in order to shrink the required milling tools. “As the name implies, the intelligent NG coil and integrated contact cooling make these devices very comfortable to work with,” says Ballbach.

Balancing System for Tools and Flywheels

Two years ago, Heggemann invested in a Haimer Tool Dynamic Comfort balancing system. Ahlers explains, “We mill here with up to 18,000rpm and use cantilevered tools. If they show an imbalance, this puts a strain on the spindle and noticeably shortens its service life. These are considerable costs that can be avoided by the balancing process on the Tool Dynamic. In addition, finely balanced tools achieve a higher level of precision and surface quality on the component due to reduced vibrations.”

The Heggemann staff wanted to balance not only the tools, but also the special products. These are the elements for flywheels, for which the client orders the balancing including documentation. After consultation with Haimer, the strategy was to install just the large standard software package to define forbidden areas for balancing. The software tool ‘Alternative Balancing Positions’ is also required here. Appropriate holders for the flywheel elements were made by the machining specialists themselves. Ahlers sums up, “We saved the required external service and thus time and money.”

When an outdated tool presetting device was to be replaced, the staff in charge tested, amongst others, Haimer’s Microset VIO linear—a fully automated presetting device.

“Due to our small lot sizes, we have to measure tools every day. That is why we wanted to keep the effort as low as possible,” says Ahlers. “The HAIMER Microset VIO has fully convinced us with all its capabilities. Especially since we now achieve a manufacturer’s consistency for shrinking and balancing, which gives us further advantages.” Amongst other things, he highlights the completed premium maintenance service contract, which covers all Haimer devices, thus minimising effort and costs.

Fully Automatic Tool Presetting

In addition to the fully automatic operation, which ensures simple operation and process-reliable measurement, it was important for the chippers to be connected to the hyperMILL CAM system used in Heggemann. It should be possible to realise a functioning process chain from the CAM to the machine, which looks like this: The programmers create a tool list for each job based on the included tool library, which is then sent to the Microset VIO linear as a measurement job for tool presetting. The operator inserts the respective tool, selects the link to the 3D CAD tool data via the touch screen, and starts the automatic measuring process.

The Haimer Microset VIO linear receives all the required information regarding X and Z dimensions as well as the starting position through the connection to the CAM system hyperMILL. The presetting device then supplies preselected actual values ​​in the complete tool set via post processor and network to the intended machine tool.

“Previously, we used different brands that are usually cheaper to buy, but do not have the same precision nor comparable life. We have found that if the quality is right—and at Haimer, it fits 100 percent—the extra investment will pay off long term,” says Ballbach, who now prefers to use Haimer devices, including Haimer tool holders.

Increasing Cooperation with Haimer

Heggemann and Haimer have been continuing to develop their partnership. When Ballbach spoke with Thorsten Böker, technical sales representative at Haimer, about the difficulty of special processing, he had a proposed solution. It concerned a bifurcated component into which two elongated grooves approximately 100mm apart must be inserted as fits. So far, this task was taken over by an oversized carbide end mill, which had to be ground free by hand to get through the first tab. Heggemann now manages this machining with Haimer Duo-Lock, a modular tool system with solid carbide exchangeable head milling cutters and extensions in various geometries and lengths.

“The switch to this tool has paid off in no time,” says Ahlers. The problem solver was ultimately the extension that Haimer has already delivered unencumbered. It saves the manual grinding of every single tool. All that needs to be changed is the HM tool head, which is considerably less expensive. In addition, the screw head can be changed quickly at the workplace, according to Ballbach.

“Because the Duo-Lock tools can be preselected with a repeat accuracy of 0.01mm due to their special interface, we do not even have to measure them after the change,” says Ballbach. In addition, the overall system runout of less than 5μm ensures best machining results and, according to Ballbach, tool life is three times as long as those of the predecessor tools.

Currently, further Haimer solutions are being tested and discussed at Heggemann. For example, the company is considering using the Haimer Safe-Lock system for heavy machining of demanding materials in the future. Its constructive design combines the frictional clamping forces of the respective clamping process with a form-fitting connection and thus reliably avoids the danger of tool pull out during roughing or power milling.

Focus on Quality

The process and results of the cooperation with Haimer not only satisfy the production staff and those responsible, the Heggemann management also appreciates the quality and reliability of their partner. CEO Christian Howe comments, “Thanks to the high-quality Haimer products, we have succeeded in further improving our production processes. The products perfectly match the requirements of our customers in the aerospace and automotive industries.”

 

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Hexagon Enhances Post-Processed Simulation, Automation Features In ALPHACAM

Hexagon Enhances Post-Processed Simulation, Automation Features In ALPHACAM

Hexagon Manufacturing Intelligence’s Production Software business has enhanced the post-processed simulation, automation, and five-axis functionality of its ALPHACAM CAD/CAM software.

The Post-processor engine now directly configures and deploys a simulation session, resulting in more realistic motion, as well as the ability to support cycles such as M6. The Automation suite has been upgraded, improving the user’s experience and productivity when creating and deploying job configurations. Whether setting up a first automation job, or whether the user is involved in complex and dynamic environments, the new setup wizards will make short work of daily production tasks.

Regarding solids machining, specifically machining solid faces directly, ALPHACAM sets a new standard by allowing direct interaction with them. The Rough/Finish command (profiling) now allows the user to directly select and machine a solid face. And if the machine supports tool compensation on custom orientations (planes), this option provides the ability to create precision parts with minimal effort, via the use of G41/G42.

Advanced five-axis functionality also has been updated to include numerous improvements, such as the ability to integrate the Toolpath Optimiser into a core cycle which can then be stored in a machining style and deployed with Automation; and the inclusion of barrel mill and double profile tools. Improvements in SWARF machining, multi-axis roughing and toolpath smoothing are also included.

The geometry offset command is now intelligent and dynamic, making all operations more productive, whether the user wants to simply retain attributes and information on the geometry, or to completely re-assign machining cycle parameters to a newly created offset.

Regarding ordering and productivity tools enhancements, a new feature of ALPHACAM provides a simple, productive and effective way to set a user-defined order in seconds.

 

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Hexagon Upgrades VISI CAD/CAM Software

Hexagon Upgrades VISI CAD/CAM Software

Hexagon Manufacturing Intelligence has upgraded its VISI CAD/CAM software, enhancing the mould and progressive die design processes, along with improvements to the Reverse module.

Designed for the mould and die market, VISI 2020.0 features a new unfolding technology, giving users the ability to work directly on the original solid part without needing to extract the model’s skin. The sheet metal part recognition, meanwhile, now provides an improved graphical representation of the part analysed, by identifying bends, planar faces and features.

Enhancements to the Reverse module provide new functionalities for both reverse and casting processes, giving greater flexibility for both processes. Features such as clipping plane management for point scanning, planar face and draft analysis on mesh data, adapting a mesh to a boundary, and best fit, improve the reverse process from point scanning to solid model generation, and manufacturing.

The software’s new Compare feature lets user compare two entities, such as a point cloud, mesh, or solid, by checking the relative distance. The graphical results show different colours in reference to the distance ranges. Also, additional Meusburger Mould Tool templates (FB, FM and FW types) are now incorporated. VISI’s Flow Analysis has been improved by a new mesh group technology specifically designed for FEM analysis.  The flow lines in VISI 2020.0 can now be shown, highlighting possible ‘hesitations’ of the filling from isochrones.

With thermal analysis becoming increasingly more important in optimising mould cooling, the Flow Thermal function has been enhanced by improved coolant flow rate suggestions, giving an indicative value for a single cooling circuit, and an improved solid mesh definition for the mould cavity block, along with each axis, to offer more accurate results.

With the new direct interface between VISI and MSC Software’s Digimat, data showing material local rigidity can be exported into Digimat for the structural FEM analysis process.

 

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Network Your Production With TNC Controls

Network Your Production with TNC Controls

Network your production with TNC controls! Designing in the CAD system, programming and preparation of the production data in the CAM system, simulation of machining on a virtual machine, tool preparation, tool measurement, tool management – all this has long been available in modern manufacturing. Article by Heidenhain.

However, the smooth exchange of data between all persons and systems involved is in no way a matter of course. Here a lot of manual work is still on the agenda—in a better case a manually initiated data transmission, in the worst case the passing on of handwritten notes.

The Machine Tool As The Focal Point In The Workshop

The workpiece is made on the machine, so all information must come together here. And from here, crucial information about the status and quality of a workpiece must also flow back into the IT systems of production—i.e. into the process chain. The machinist responsible for the quality of the components and for staying on schedule must have access to all the data and must be able to apply his experience in manufacturing to the process chain.

There are many ideas for the networking of all persons and systems involved in the process. But under these considerations, making the machine control in the workshop the focal point of a company network has a very special charm.

Current Tool Data Always And Everywhere

The fixed blanks are lying on a pallet at the machine for pending work. Calibrated tools are already loaded in the machine’s tool magazine. They are clearly identified by a code on the tool holder. The TNC operator used a scanner to read this identification when he loaded the tool magazine, so the TNC 640 knows which tools are available in the machine. The data comes directly from the tool management over the Heidenhain DNC interface.

Using the Remote Desktop Manager, the TNC operator can directly access the CAM system from the TNC 640 control. For its part, the CAM system returns to the tool database for program creation. Using the Batch Process Manager of the TNC 640, the TNC operator can now schedule execution of the production job on the machine. In the Batch Process Manager, NC programs and the position of the clamped workpiece on the pallet are linked with respect to the order and sorted into the list of open orders by priority.

The Batch Process Manager enables the TNC operator to schedule several production orders simultaneously. The control supports this by once again comparing the tools used in the NC program with the tools actually available on the machine. The control then reports any tools that are missing, and states the estimated machining time. The TNC operator can then, for example, output a list of tool differences: this list contains only those tools that still need to be prepared.

The information about the estimated machining time can also be used for further order planning, such as subsequent jobs for the machine or the further logistics of the finished parts. This information is also used together with information from the tool management to order new tools. The new StateMonitor software supports the TNC operator in this regard. StateMonitor captures the data of connected machines, presents a real-time view of the machine status, and can send messages to computers throughout the company as well as to mobile devices. StateMonitor also uses the DNC interface.

The tool preparation station then immediately receives orders for any additionally required tools. This also applies to series production runs that are currently underway. StateMonitor can send a message to the tool preparation station if a tool’s age is approaching a critical value and this is detected by the NC program. Based on the data stored in the tool management, the tool preparation station can then promptly prepare new tools in the tool presetter for calibration. In this case as well the data of the exact tool settings are sent to the tool management. The pre-set tools are given their own code on the tool holder for unambiguous identification. The CAM program and the virtual machine then also have access to this exact data.

The final, automatic workpiece measurement on the machine delivers important data for quality assurance. This data can simply be archived or it can be evaluated. Naturally the data is also centrally available to all other systems, meaning that from the NC program to the tools, all links of the process chain can be optimized.

Connected Machining: Flexible connections for individual circumstances

The core components of Connected Machining are the Heidenhain DNC interface, the Remote Desktop Manager, and the StateMonitor software. The Heidenhain interface establishes the connection to enterprise-resource planning systems and production-activity control systems, and also links StateMonitor to the company network, whereas the Remote Desktop Manager provides access to all Windows applications. Also, numerous useful functions for data presentation, such as viewers for PDFs and graphic files as well as for CAD files in STEP or IGES format, are a standard feature of TNC controls from Heidenhain. A browser is also installed on the control. All that’s left is to simply connect the control to the company network over an Ethernet connection.

The solutions provided by Connected Machining are universally adaptable to the individual circumstances of a production department, meaning that every company can design its process chain according to its own needs and desires. The various functions and software solutions thus link the production department to a process chain with a uniformly digital flow of information. This can be done completely independently of the solution chosen, regardless of the respective downstream systems. Our goal is the greatest possible flexibility for our customers. They can adapt, configure, and implement the solutions from Heidenhain themselves.

 

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Directing Investments In The Right Way

Directing Investments In The Right Way

Procurement of new machines is not the only way of increasing production capacity. The right tools and suitable software can also generate up to 85 percent gains in productivity. What if the order book is full and the company has reached the limit of its capacity? When a company finds itself in this situation, the question that arises is: Whether to procure new machines or to explore how to make better use of the existing stock of machine tools. There are ways of doing this. For instance “Parabolic Performance Cutting” (PPC) is a production technique that can accelerate the finish machining process by a factor of nine. By Hoffmann Group.

Expand the existing capacity or start to turn down orders? Many companies find themselves in this dilemma: Every time a company turns down an order there is the risk the customer may not consider this company for future orders. So essentially there is no alternative but to continue to accept every new order. However at some point the existing stock of machine tools will reach its limits. What then? Is it justifiable to procure an additional machine when it is uncertain how long the surge in orders will be sustained? Moreover there is a time lag of several months between ordering and receiving a new machine. So how can the new machine address the current production bottleneck? Many Production Managers suffer sleepless nights wrestling with such questions. Indeed, new machines represent substantial investment, often a seven-figure sum – they need space, personnel to operate them, and are not immediately ready for productive use. Alternatives by which a relatively small investment and no loss of time can achieve significantly more from existing productive resources are therefore very attractive. PPC milling is one such technique. The success story is already well established. For instance, Koller Formenbau GmbH of Dietfurt in the Altmühltal, Germany, has used PPC milling cutters supplied by the Hoffmann Group to reduce the finish machining time for geometrically ruled surfaces from 100 hours to 15 hours.

Massive Reductions In Finish Machining Times

PPC is also called barrel milling. Similarly to that of a ball-nosed slot drill, the main cutting edge of a PPC milling cutter is curved as an arc of a larger radius circle. Whilst for a classic ball-nosed slot drill the effective radius of the tool is only half the diameter, a PPC milling cutter has a much greater effective radius, up to 1000 millimetres, thus permitting a significantly greater engagement length on the workpiece. A barrel milling cutter achieves a line skip up to nine times greater than that available using a ball-nosed slot drill of the same tool diameter, thus placing less stress on both the tool and the machine. If on the other hand the same line skip is maintained a surface quality up to 80 times better can be achieved. The Hoffmann Group is currently offering a portfolio of tools with effective radii up to 1000 millimetres. Even larger radii are conceivable and could be implemented as tools, but the very long engagement length would demand very high contact pressures. The resulting displacement of the tool would have a negative effect on precision, which of course in a finishing process cannot be compromised. The Hoffmann Group also offers special solutions with effective radii different from those in the catalogue, to allow the customer to gain the optimum benefits from PPC for specific applications. In order to fully exploit the advantages of PPC, a radius in the range of 700 or 800 millimetres has generally been found to offer the best solution. Very often the best solution depends not only on the component but also on the machine tool in use.

Different Profiles And Approach Angles

PPC is particularly effective when the tool profile is exactly suited to the workpiece surface contour. Therefore, depending on the application, up to four different tool profiles are necessary for optimum machining of workpieces and free-form surfaces with highly complex surface geometries. This is because surfaces with interference contours, large areas, deep cavities or flat faces each demand different tool profiles. The Hoffmann Group therefore currently offers the following principal cutting edge profiles: “straight”, “tangential”, “conical“ and “stub point conical”; each representing a specialised solution for machining particular types of surface. For all profiles except for the straight profile the tool is also mounted at an oblique angle – and the selected approach angle also makes a difference. Therefore the Hoffmann Group offers conical and stub point conical PPC milling cutters with three different approach angles. These allow the programmer to use the optimum type of milling cutter for the specific application. Depending on the component, for instance steeper approach angles allow interference contours to be avoided.  Or the use of a machine tool that has a large headstock may require the choice of a tool with a larger approach angle.

CAD/CAM With Tooling Database

In contrast to ball-nosed slot drill cutting, PPC is more dependent on software. For classic ball-nosed slot drill cutting the CAM software requires only a small amount of information to calculate an appropriate milling strategy: It is sufficient to declare the tool diameter, tool length and the information that the relevant tool is a ball-nosed slot drill. These data can also be processed manually. The more complex tool profiles of PPC on the other hand can be calculated only in combination with CAM software that offers “barrel milling” as a strategic option. In addition the software must have available a tooling database which holds the exact geometries of the PPC milling cutters.

Furthermore, because for PPC the tools are aligned obliquely to the workpiece, this process can be employed only in conjunction with a 5-axis milling machine. As 5-axis machines come increasingly into use, PPC milling is now really taking off. In any case it is not always necessary to control all 5 axes simultaneously. Often, once the tool has been set up, the draft angles can be machined with 1 or 2 axes clamped, in order to achieve even better results. At one time there were only a few software programs that offered “barrel milling” functionality. That too has changed in recent years. Koller Formenbau for instance already had a 5-axis machine in use and operated Hypermill software, and only then did it seek suitable barrel milling cutters. At a moderate expense the company has been able to achieve up to 85 percent gains in productivity thereby significantly increasing the productive capacity without having to procure new machine tools.

Increasing Areas Of Application

A classic area of application for PPC is finish machining of complex components and free-form surfaces in machine tool manufacture and in tool and die production. In medical technology, turbine technology and aerospace, PPC is attracting increasing interest. A relatively new area of application for instance is the finish machining of workpieces produced by additive manufacturing. 3D printing permits particularly complex workpieces to be produced in a single production operation. However, workpieces produced on a 3D printer fall well short of the surface quality required for contact faces. Such workpieces must be finish machined. PPC was conceived for exactly such applications. And not least because a variety of different materials are often used for the 3D printing process, the Hoffmann Group has extended its PPC milling cutter family to cater for machining a wide range of materials. PPC milling cutters for machining aluminium were demonstrated for the first time at AMB 2018. The new milling cutters are particularly sharp-edged and can also be used for machining plastics. This significantly extends the existing portfolio over a wide range of applications.

PPC As A Productivity Solution

Companies which direct their investment into alternative paths can achieve substantial increases in productive capacity at a relatively small outlay, without adding to their existing stock of machine tools. CAM-controlled production using PPC is such an alternative. PPC permits genuine step function gains in productivity with a relatively modest investment in software and tools.

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CNC Machines Market Forecast

CNC Machines Market Forecast

The size of the global CNC machines market is expected to hit USD 100.9 billion by 2025, according to a new report by Grand View Research, Inc.

With a rising CAGR of 6.8 percent over the forecast period of 2014 to 2025, the growth in the market is due to an increasing need for reduced operating costs, manpower shortages and the requirements for minimal errors in components.

Technological advancements are also spurring the use of CNC machines in the development of highly intricate models/components with a definitive finish. This has in turn given rise to the adoption of CNC technology in lathe, milling, laser, grinding, and welding machines. The integration of CNC machines with computer-aided manufacturing (CAM) also helps in lessening the time needed for manufacturing of work pieces and enables hassle-free production of components.

Additionally, commercial demand for advanced, compact-sized CNC machines with automatic tool changers and multi axis machining technology is expected to increase and numerous large manufacturing facilities are adopting CNC lathes to perform operations such as cutting, drilling, knurling, deformation, facing, and turning.

Overall, the milling machines segment is estimated to post the highest CAGR of 9.5 percent during the forecast period because of their multi-functionality and reduced time requirement while the industrial segment will lead market growth till 2025 with a projected valuation of USD 25.17 billion. In terms of regional growth, the Asia Pacific region is projected to witness tremendous growth over the forecast period because of the rise of manufacturing and key contributors to the growth of the sector include Amada Co., Ltd., DMTG Corporation, Haas Automation, Inc., Okuma Corporation and Yamazaki Mazak Corporation, among several others.

 

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Hypertherm Adds New Features To Rotary Tube Pro Software With Version Update

Hypertherm Adds New Features To Rotary Tube Pro Software With Version Update

Hypertherm has announced a minor version update of the Rotary Tube Pro software that makes it easier to design and cut tube and pipe parts with no 3D CAD experience required.

The new minor version update includes a number of new features designed to speed the programming process. For example, automatic nesting is now standard, allowing software users to nest multiple quantities of the same part or different parts on stock tube. Users can add parts to the part list and build a stock list for nesting, maintain the seam orientation during nesting, add part spacing, and choose how the software selects stock.

Other new features include the ability to store multiple parts and nests, plus an advanced edit feature that allows uses to manually adjust preferences like the lead size and position, along with cut sequence. The software also includes features that allow users to pin commonly used lead styles to the top of the list for quick access and offers more powerful reports to better track nests and stock usage.

“Instead of moving tube and undertaking multiple steps—measuring, sawing, drilling, etc.—Rotary Tube Pro really streamlines the production process,” explained Tom Stillwell, a project manager for Hypertherm’s CAD/CAM software team. “And though it is already easy to use, the enhancements introduced with this minor update of Rotary Tube Pro make the process of programming and completing jobs even easier than before, giving fabricators and manufacturers the ability to work more efficiently, boost productivity, and reduce operating costs even further.”

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Vero Software, FASys And SPRING Technologies To Unite Under Hexagon Brand

Vero Software, FASys and SPRING Technologies To Unite Under Hexagon Brand

Hexagon’s Manufacturing Intelligence division has announced the formation of its Production Software business, comprising Vero Software, FASys and SPRING Technologies. The move, which sees the three acquisitions adopting Hexagon’s corporate identity, reflects Hexagon’s broadening expertise in the production technology space.

Hexagon acquired Vero Software, a specialist in CAD and CAM software, in 2014 and has continued to expand and diversify its offering. The 2017 acquisition of FASys brought tooling and resource management software and shop-floor automation and integration expertise into the portfolio. SPRING Technologies, acquired in 2018, provides CNC simulation technology for G-code verification and workflow optimisation. Combining components of this rich portfolio of technology, Hexagon has already utilised this expertise to develop solutions for reverse engineering and on-machine measurement.

“Over the last five years our available technology and solutions have evolved considerably from the CAD CAM heritage of Vero,” explained Steve Sivitter, CEO of the Production Software business. “We’re increasingly focused on developing product synergies that will help customers improve quality and productivity. Our technology experts from Vero, FASys and SPRING have been working very closely together for some time, so operating together as a single entity is a natural step for us. We’re all excited at the prospect of what’s possible now creating innovative manufacturing intelligence solutions in the production software space.”

Norbert Hanke, President of Hexagon’s Manufacturing Intelligence division, added that: “The formation of the Production Software business complements our design and engineering and metrology businesses, enabling us to build unique solutions for our customers in manufacturing. As we develop this approach further, our experience of leveraging data from all phases of the manufacturing process will help create the Autonomous Connected Ecosystems (ACE) that will enable Smart Factories.”

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