Flexibility in perfection at clamping technology specialist

Photo: engineer Robert Fraunberger, x-technik

When it comes to process optimisation in industrial production, it is hard to overlook the gripping and clamping technology specialist Schunk. The family-owned company stands out for its innovation, top quality, and solution expertise. This is also reflected in their own manufacturing, where the team works daily to produce the best possible components and products on high-quality machine tools, ensuring both process reliability and economic efficiency. Alongside CAM programming and automation, the simulation of manufacturing tasks before real machining, using Vericut, plays a crucial role.

When it comes to equipping robots and production machines, Schunk is a go-to partner for many industries worldwide. Whether it is smartphones, aircraft, vehicles, machines, knee joints, or nasal sprays, high-tech components from Schunk are often key players in their production.

Founded in 1945 by Friedrich Schunk as a small mechanical workshop, Schunk is now an international technology company with 3,700 employees in over 50 countries and is led by the third generation of the family — Kristina and Henrik Schunk. The company boasts extensive expertise in clamping technology for tools and workpieces, gripping technology, and automation technology.

Process optimisation
Fatih Gülgönül, head of engineering, said: “Our components, applications, and services support our customers and partners globally in process optimisation. In addition to individual high-tech components, we provide intelligent complete solutions for robotic systems as well as for various production and automation processes — all from one source for custom client applications.”

Due to its extensive product portfolio of over 13,000 standard components and 2,000 customer-specific parts, Schunk’s main production sites in Lauffen and Hausen — north of Stuttgart — emphasise high manufacturing depth. Production manager Steffen Gotzmann, highlighting the importance of in-house manufacturing at Schunk, said: “For us, each step of the process must deliver maximum efficiency with the highest quality. That is why we keep all necessary competencies in-house and control every process step ourselves.”

At the Lauffen plant alone, about 250 skilled workers and over 150 CNC machines work in three shifts to efficiently produce various components, mainly for clamping technology, from different materials. A walk through the production halls offers a great insight into Schunk’s high-quality standards. In addition to well-organised production lines, the cleanliness and tidiness of workstations stand out. Whether turning, milling, grinding, or eroding, only top-tier machines from leading manufacturers are used.

Mr Gotzmann said: “All core machines in our main production lines are CAM-programmed. This keeps downtime to a minimum.” Schunk employs 68 CAM programmers — nine of whom focus on custom clamping technology for smaller batches and order-specific production. He added: “In this department alone, we create around 3,000 NC programs annually for approximately 2,000 custom-developed, designed, and produced products.”

Cost-effective production
For both department heads, maximum process reliability is critical for a cost-effective production process, as waste is something Schunk cannot afford. Alongside CAM programming and automation, the simulation of production tasks before actual machining plays a significant role.

Discussing the importance of Vericut simulation and optimisation software to Schunk, Mr Gülgönül said: “Machine simulation is a key element for a safe machining process. The simulation integrated into the CAM system is not enough for us. It is crucial that the simulation we run in the office perfectly matches the real processes on the machines, including the kinematics of the equipment. Only then can we ensure that what we have programmed will be executed exactly as intended.”

Mr Gotzmann explained: “Vericut provided the complete package — the software delivers exactly what we need for efficient and safe production, and the Vericut team offers reliable support with its expertise.” CAM administrator Juri Buling said: “When machines are idle, it costs a lot of money, and we want to avoid that. That is why investing in Vericut was the logical step.”

With Vericut, the entire clamping situation — including the blank, clamping tools, machining tools, and the machine itself — can be simulated. According to Mr Buling, this virtual machining process has significantly increased process reliability in Schunk's production.

An integral part of the process chain, a key feature of Vericut, according to Hans Erkelenz, managing director of CGTech Germany, who led the project, is the fully independently developed software: “Since 1988, Vericut has been considered a benchmark in machining production, leading the field in machine simulation, verification, and optimisation for all types of CNC machining, as well as additive and hybrid manufacturing processes. The software operates independently and integrates with all common CAM systems.”

100% accurate kinematics
Moreover, its core simulation engine is the fastest and most accurate in the NC simulation field, and currently, Schunk simulates 34 machine tools with Vericut at its base in Lauffen. Mr Buling continued: “We can simulate and optimise all our machines, including automated multi-channel turn-mill centres — with 100% accurate kinematics. We can also simulate features like engraving or transferring parts from main to counter-spindle — so Vericut is an essential part of our process chain.”

Mr Erkelenz added: “Vericut simulates the real machine environment with precise multi-axis and high-speed movements, multiple setups, and complex tool shapes, providing insights into potential collisions with holders or fixtures.”

Due to the wide variety of customer-specific solutions at Schunk, frequent setups are necessary. Mr Gotzmann added: “Thanks to CAM programming and Vericut simulation, we manage to keep these setup and downtime as low as possible. The NC program is already prepared on the machine, and we know it works because we have verified it with Vericut.” This allows Schunk to use available resources as efficiently as possible.

According to the production manager, having a verified NC program also gives machine operators more confidence, allowing them to run new parts faster and more effectively. “Not to mention that we can optimise programs through Vericut without having to test them directly on the hardware — a significant advantage in times when continuous productivity increases are essential to remain competitive.” Optimising NC programs is especially crucial for series parts.

Since implementing Vericut, collisions have been eliminated at Schunk, and unnecessary costs due to downtime have been avoided. Mr Gülgönül continued: “The project was challenging, so it is all the more remarkable that Vericut fully met the timeline.”

Mr Erkelenz said: “Schunk is undoubtedly a special client for Vericut due to its scale and tight schedule. Thanks to excellent support from Schunk, we were able to integrate the first 30 machines into the simulation within a year — this was challenging for our entire team! I am proud we were able to meet all expectations 100%.”

The next steps for Schunk are already clear, as Mr Buling concluded: “Our goal is to increasingly digitalise all production sites and equip them with Vericut — ultimately securing our competitiveness for the future.”