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From the point of view manufacturer, machine tools fulfil technological requirements of manufacturing processes for part geometrical dimensions, shaping and material property change. Main machine tool functions are axis motions with sufficient power reserve drives to technological process loads, consuming energy. Participation of manufacturing systems and processes for sustainable life in industrial applications and limiting earth warming up is required. This paper is responding to a scientific demand in setting development trends for manufacturing systems, processes and environment. Here a scientific question arises: which technological requirements and machine functionalities to machine tool characteristics lead to their lowest resource consumption / losses and part manufacturing costs? The machine tool manufacturer methodology is following a relation and dependency analysis, combined with functional synthesis and resource optimization. The machine tool user applies the key performance indicator "Overall Equipment Effectiveness OEE" integrates efficiency values for productivity, availability, quality, targeting minimal part manufacturing costs.

Microassembly of piezoceramic fibers in micro cavities at the surface of sheet metal is a novel approach for high volume production of smart adaptronic structural metal parts. In this paper a technology, manufacturing processes and characterization results of metal sheets with an active piezo-metal substructure based on directly integrated piezoceramic fibers are described. The processes include micro-milling of cavities in sheet metal, precision grinding of piezoceramic fibers, PECVD insulating layers with high dielectric strength, microassembly and force-locked joining by forming. In experiments, measurements of the surface roughness and geometric parameters of the piezoceramic fibers and micro cavities were performed. Further, the electrical properties of the insulation coatings were measured. The sensor function of the piezo-metal substructure was proven by a mechanical excitation resulting in a proportional measured sensor signal

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The technique joining by forming allows the structural integration of piezoceramic fibers into locally microstructured metal sheets without any elastic interlayers. A high-volume production of the joining partners causes in statistical deviations from the nominal dimensions. A numerical simulation on geometric process sensitivity shows that the deviations have a high significant influence on the resulting fiber stresses after the joining by forming operation and demonstrate the necessity of a monitoring concept. On this basis, the electromechanical behavior of piezoceramic array transducers is investigated experimentally before, during and after the joining process. The piezoceramic array transducer consists of an arrangement of five electrical interconnected piezoceramic fibers. The findings show that the impedance spectrum depends on the fiber stresses and can be used for in-process monitoring during the joining process. Based on the impedance values the preload state of the interconnected piezoceramic fibers can be specifically controlled and a fiber overload.