Flexibility in Perfection – Schunk ensures maximum process reliability through NC simulation with Vericut
When it comes to process optimisation in industrial production, it’s 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’s smartphones, airplanes, 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, today Schunk is an international technology company with 3,700 employees in over 50 countries and is led by the third generation of the family, Kristina I. and Henrik A. Schunk. The family-owned company boasts extensive expertise in clamping technology for tools and workpieces, gripping technology, and automation technology. “Our components, applications, and services support our customers and partners globally in process optimisation,” emphasises Fatih Gülgönül, Head of Engineering. He adds, “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.”
High Manufacturing Depth, High Quality Standards
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. “For us, each step of the process must deliver maximum efficiency with the highest quality. That’s why we keep all necessary competencies in-house and control every process step ourselves,” says Production Manager Steffen Gotzmann, highlighting the importance of in-house manufacturing at Schunk.
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 orderliness of workstations stand out. Whether turning, milling, grinding, or eroding, only top-tier machines from leading manufacturers are used.
“All core machines in our main production lines are CAM-programmed. This keeps downtime to a minimum,” says Gotzmann. Schunk employs a total of 68 CAM programmers—nine of whom focus on custom clamping technology for smaller batches and order-specific production. “In this department alone, we create around 3,000 NC programs annually for approximately 2,000 custom-developed, designed, and produced products,” Gülgönül explains.
Process Reliability is Key
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. “Machine simulation is a key element for a safe machining process. The simulation integrated into the CAM system is not enough for us. It’s 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’ve programmed will be executed exactly as intended,” Gülgönül explains why Schunk uses the Vericut simulation and optimisation software.
“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 their expertise,” explains Steffen Gotzmann. CAM administrator Juri Buling adds: “When machines are idle, it costs a lot of money, and we want to avoid that. That’s 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 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.” Moreover, its core simulation engine is the fastest and most accurate in the NC simulation field.
Currently, Schunk simulates 34 machine tools with Vericut in Lauffen: “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,” says Buling. Erkelenz adds: “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.”
Minimised Setup and Downtime
Due to the wide variety of customer-specific solutions at Schunk, frequent setups are necessary. “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’ve verified it with Vericut,” Gotzmann explains. 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.
Project Timelines Met
Since implementing Vericut, collisions have been eliminated at Schunk, and unnecessary costs due to downtime are avoided. “The project was challenging, so it’s all the more remarkable that Vericut fully met the timeline,” emphasises Fatih Gülgönül. “Schunk is undoubtedly a special client for Vericut due to its scale and tight schedule,” notes Erkelenz. “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’m proud we were able to meet all expectations 100%.”
The next steps for Schunk are already clear, as Buling concludes: “Our goal is to increasingly digitise all production sites and equip them with Vericut—ultimately securing our competitiveness.”
About Vericut
Vericut specialises in numerical control (NC/CNC) simulation, verification, optimisation, post-processing, and analysis software for manufacturing. Vericut also offers programming and simulation software for composites automated fibre-placement, tape-laying, and drilling/fastening CNC machines. Vericut software is used by companies of different sizes in all industries. Established in 1988, and headquartered in Irvine, California; Vericut has offices worldwide.
For more information: visit our website at vericut.com/en-gb, call +44 (0) 1273-773538, or email marketing.uk@cgtech.com
