hp tooling 2020 #1

The journal of hp tooling is an english, global publication on all aspects of high precision tools, accessories and their applications.

The journal of hp tooling is an english, global publication on all aspects of high precision tools, accessories and their applications.


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ISSN 2628-5444<br />

high precision <strong>tooling</strong><br />

Machine Tools, PCD, PVD, CVD, CBN, Hard Metal <strong>2020</strong> - 1<br />

Reishauer 213.5x201.5mm HP Tooling.indd 1 17.02.<strong>2020</strong> 09:50:06<br />

■ Opportunities for cutting tool manufacturers ■ Powerful tools for electric motor production ■<br />

■ Medical screws ■ Complete turnkey solutions from a single source ■ GrindTec preview ■

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2 No. 1 • February <strong>2020</strong>

editorial<br />

Score with creativity<br />

The heart of<br />

metal working<br />

beats in Stuttgart!<br />

Eric Schäfer<br />

editor-in-chief<br />

The year <strong>2020</strong> will - as is<br />

already foreseeable - be a<br />

challenge for the global<br />

economy and thus also for<br />

the machine tool and the<br />

machine tool industry and<br />

its customers. Growth will be<br />

modest worldwide, if not declining in many places. But<br />

difficult times are always an opportunity to reinvent<br />

oneself and to score points with innovations and<br />

creative solutions.<br />

First results of these creative efforts can be seen at<br />

GrindTec <strong>2020</strong>, the World Trade Fair for Grinding Technology.<br />

Although grinding technology is also closely connected<br />

with the automotive and mechanical engineering<br />

industries, the overall market for grinding applications<br />

is still strong. One can certainly expect trend-setting<br />

processes and advanced technologies from the exhibitors<br />

at the trade fair. In this issue we will give you a preview<br />

of what the manufacturers will present at GrindTec. We<br />

are particularly looking forward to the world premiere of<br />

the laser machine from the sharpening specialist Vollmer.<br />

The further development of additive manufacturing is<br />

a topic for the future, which we also turn our attention to<br />

in this issue. We report on the possibilities that additive<br />

manufacturing offers cutting tool manufacturers.<br />

It is equally interesting how the limits of additive<br />

manufacturing are being pushed back by new metal<br />

powders and components. Furthermore, we inform<br />

you about new manufacturing solutions in medical<br />

technology, report on the cost-efficient series production<br />

of turbochargers and present powerful tools for the<br />

production of electric motors.<br />

Don't forget to visit our website<br />

www.harnisch.com and pick up the news between<br />

this and our next issue of journal of <strong>hp</strong> <strong>tooling</strong>!<br />

ORDER<br />

YOUR<br />

TICKET<br />

NOW!<br />

International exhibition<br />

for metal working<br />

15.–19.09.<strong>2020</strong><br />

Messe Stuttgart<br />

Germany<br />

Eric Schäfer<br />

editor-in-chief<br />


table of contents<br />

cover story<br />

The perfect symbiosis between machine and <strong>tooling</strong><br />

Modern thinking has shown that machine tools and <strong>tooling</strong> can’t be seen as separate entities 6<br />

materials & tools<br />

Pushing forward boundaries of additive manufacturing with new metal powders and components 9<br />

Powerful tools for electric motor production 10<br />

Reliable, cost effective serial production of turbochargers 14<br />

50 years Borazon - CBN grinding wheels 16<br />

Medical screws: efficiency = saving time while increasing precision and quality 18<br />

Partner for carbide rods and special solutions 21<br />

«Solutions in new dimensions» - HOLZ-HANDWERK fair 21<br />

Dressing tools and digital solutions 22<br />

TIGRA with interesting innovations at the GrindTec show <strong>2020</strong> 24<br />

LACH DIAMANT looks back on 95 years - third part - Hard turning 26<br />

processes<br />

Additive manufacturing: opportunities for cutting tool manufacturers<br />

by Thomas Götz, Andreas Gebhardt and Dr. Marco Schneider 36<br />

Efficient processing for the benefit of customers and patients 39<br />

A thoroughly economic alternative - CBN generating grinding 40<br />

Fine abrasive waterjet bridges the gap - waterjet cutting 42<br />

machining center<br />

Full-line supplier VOLLMER introduces its key trio 43<br />

The easy route to production autonomy 44<br />

Growing up in the cutting tool industry 46<br />

HSC milling: highly productive, high-volume production for surgical instruments 48<br />

Where craftsmanship and high-tech go hand in hand 50<br />

Complete turnkey solutions from a single source 52<br />

Automated adaptive milling technology and new minimal-quantity lubrication process 54<br />

components<br />

Lubricant manufacturers count on quality and sustainability 55<br />

More time to generate revenue 56<br />

departments<br />

fairs 29<br />

companies 31<br />

impressum & company finder 58<br />

4 no. 1, <strong>2020</strong>, March

Ultimate. Universal.<br />

Ultra-quick.<br />

The New Silverline –<br />

Now even better!<br />

For more information:<br />

cutting.tools/en/silverline<br />


CERATIZIT is a high-technology engineering<br />

group specialised in cutting tools and<br />

hard material solutions.<br />

Tooling the Future<br />


cover story<br />

The perfect symbiosis between<br />

machine and <strong>tooling</strong><br />

Modern thinking has shown that machine tools and <strong>tooling</strong><br />

can’t be seen as separate entities<br />

The Swiss company, Reishauer,<br />

has shaped industrial history<br />

since its foundation in 1788 when<br />

the company was initially set up<br />

as a smithy to make hand tools.<br />

In 1863, a “taps-lathe” was build to<br />

make the first threading taps with a<br />

radial relieving unit. With the growth<br />

of the tap market share, the company<br />

was well-positioned to develop<br />

its first grinding machine in 1928: a<br />

thread-grinding machine with a single<br />

rib vitrified grinding wheel. The<br />

trig ger to develop this machine was a<br />

lack of equipment on the market that<br />

could deliver the necessary accuracy<br />

for thread gauges. At this time, the<br />

mar ket had no machine on offer that<br />

could efficiently grind threading taps.<br />

Hence, the dissatisfaction with existing<br />

technology triggered Reishauer<br />

engineers to develop a new type of<br />

thread-grinding machine. In 1931,<br />

the first machine went into production<br />

that was able to grind from solid<br />

hardened blanks, including the grinding<br />

of the relief angle.<br />

1-Continuous generating gear grinding process<br />

This thread-grinding machine required<br />

precision gears for setting the<br />

pitch of the different threads on taps.<br />

The precision of the threads was directly<br />

related to the accuracy of the<br />

gears within the machine. Again, it<br />

was the dissatisfaction with the status<br />

quo of technology that drove the engineers<br />

to find a better way to manufacture<br />

high precision gears. This dissatisfaction<br />

led them to the invention<br />

of a new idea of gear grinding:<br />

the continuous generating process<br />

of grinding gear profiles, a process<br />

Reishauer has been famous since. This<br />

process delivered gears that were more<br />

accurate, cheaper, and faster to manufacture<br />

than by the previous methods<br />

of tediously grinding gears tooth gap<br />

by tooth gap.<br />

Nevertheless, it took fifteen years<br />

of intensive development work, and<br />

in 1945 the first continuous-generating<br />

gear grinding machines were used<br />

in-house and sold to third parties. The<br />

success of the thread and gear-grinding<br />

machines prompted Reishauer to<br />

halt tool manufacture and concentrate<br />

exclusively on building machine<br />

tools. Moreover, as the cost per<br />

gear ground diminished with increasing<br />

efficiency of the generating grinding<br />

process, automotive gear grinding<br />

gained more interest. In 2006,<br />

the company decided to concentrate<br />

fully on gear-grinding machines when<br />

the manufacture of thread grinders<br />

stopped.<br />

In 1998, a familiar pattern of dissatisfaction<br />

with the status quo repeated<br />

itself, but in reverse order. The available<br />

tools for the gear-grinding machines,<br />

both grinding wheels and diamond<br />

dressing tools, could no longer<br />

match the performance potential<br />

of the continuous generating machines,<br />

particularly in terms of accuracy.<br />

For this reason, Reishauer began<br />

its production of diamond dressing<br />

tools and laid the foundation of its<br />

performance portfolio that included<br />

machine tools and the required <strong>tooling</strong>.<br />

In 2008, a grinding wheel factory<br />

was founded, shortly followed in<br />

2012 by a manufacturing site for fixturing.<br />

These steps ensured the full<br />

potential of the machine tools to<br />

deliver consistent quality at low costs<br />

per gear ground. Furthermore, this put<br />

Reishauer into a position of being able<br />

to control all factors that influence<br />

the quality of the continuous generating<br />

grinding process. The mindset to<br />

view <strong>tooling</strong> and machine tools separately<br />

no longer corresponded to modern<br />

thinking.<br />

2-Inside of gear-grinding machine<br />

with <strong>tooling</strong><br />

grinding<br />

wheel<br />

diamond<br />

dresser<br />

workholding<br />

(2x)<br />

Grinding Wheels<br />

As the Greek philosopher Aristotle<br />

stated: “Every tool achieves perfection<br />

by serving one, instead of many purposes.”<br />

The company strictly adheres<br />

to this advice and limits itself to the<br />

manufacture of <strong>tooling</strong> that serves<br />

only one purpose: to grind high precision<br />

gears on Reishauer machines. The<br />

grinding wheels, also called “threaded<br />

6 no. 1, <strong>2020</strong>, March

cover story<br />

wheels” once they have been profiled, play a vital role in<br />

the generating process. The grinding machine delivers the<br />

kinematics, i.e., the high precision movements that control<br />

the cutting path of the grinding wheel. For its part,<br />

the grinding wheel must transfer these precision movements<br />

onto the gear to be ground, by grinding this precisely<br />

to a predetermined dimension, surface finish, and structure,<br />

and within a short cycle time and without causing<br />

thermal damage. To meet these requirements, Reishauer<br />

has built one of the most modern and most automated<br />

grinding wheel factories in the world in Switzerland. In<br />

contrast to other wheel makers, Reishauer had the advantage<br />

of dealing with only a few wheel dimensions and only<br />

one field of application, which made possible this high degree<br />

of automation. The extensive use of robotics ensures<br />

uncompromising homogeneity of the finished products as<br />

Contrary to conventional one-sided pressing operations,<br />

Reishauer wheels are made on presses and mold setups<br />

that allow pressing from top and bottom on a simultaneous<br />

down and upstroke press. This process ensures that<br />

the resulting hardness gradient across the full width of the<br />

wheel is minimal.<br />

The loading of a kiln cart serves as a concrete example.<br />

Vitrified grinding wheels are fired for several days<br />

at a temperature marginally below 1,000° C (1,800° F),<br />

following a carefully established temperature curve, with<br />

defined ramp, holding and cooling-down temperature<br />

gradients. Before firing in the kiln, a robot places each<br />

grinding wheel at a specific position on the kiln cart (illustration<br />

5). The robot reads and records the position of each<br />

wheel, which can be retraced if required in the future.<br />

3-Machine-readable laser engraving on grinding wheel<br />

5-Robot loading of a kiln cart<br />

established grinding processes in customer plants that depend<br />

on this high degree of homogeneity from lot size to<br />

lot size. After pressing, each grinding wheel is laser-marked<br />

as soon as it leaves the pressing mold. This laser mark is a<br />

machine-readable, indelible “birth certificate” (Illustration<br />

3). This marking allows total control over each subsequent<br />

processing step and makes each grinding wheel traceable<br />

to ensure the tool delivers the consistent performance that<br />

end-users demand.<br />

4-Pressing grinding wheels from both sides<br />

Knowing the position of each wheel during the firing process<br />

in the kiln, and subsequently measuring the hardness<br />

(modulus of elasticity) of each wheel, allows working out<br />

the firing conditions in such a way that all wheels have the<br />

same resulting hardness.<br />

The comprehensive process monitoring covers all subsequent<br />

manufacturing steps, such as hardness testing, turning,<br />

and speed testing. Over-speeding, i.e., speed testing<br />

each wheel, ensures the safety of the grinding processes at<br />

end users. In line with the relevant safety laws, Reishauer<br />

subjects every wheel to an automated over-speeding test<br />

with a safety factor of 1.5 times the permissible operating<br />

speed. Again, given the machine-readable wheel markings,<br />

each wheel speed test remains traceable.<br />

Diamond dressing tools in symbiosis with the<br />

grinding wheel and the machine tool<br />

Before a grinding wheel can deliver the required accuracy<br />

and material removal rate, it must be dressed by a hig<strong>hp</strong>recision<br />

rotary diamond dressing tool. The dressing of<br />

the threaded wheel for continuous generation, grinding<br />

meets several requirements. Firstly, dressing imparts a perfect<br />

worm profile and makes the threaded wheel free cutting.<br />

Secondly, dressing removes any impurities or wear<br />

no. 1, <strong>2020</strong>, March<br />


cover story<br />

that may have been instigated by the grinding process,<br />

such as the wheel pores stay open to accommodate grinding<br />

oil and can remove the chips that have been gener -<br />

ated during the high material removal rates. Diamond is<br />

the ideal material for dressing tools, as it is much harder<br />

than the aluminum oxide of the threaded grinding wheels<br />

employed in the process.<br />

Only rotary dressing rolls can match the high requirements<br />

regarding geometry, service life, and efficiency<br />

during the dressing process. Illustration 6 shows a multistart,<br />

reverse-plated diamond dresser. Additionally, this<br />

dresser features an RFID chip that can communicate with<br />

the machine.<br />

frequent part changeover is required. This system reduces<br />

set-up times and increases productivity, translating into<br />

economic use of the continuous gear-grinding machine for<br />

small or large batch production.<br />

As described for the diamond dressing tools, the fixturing<br />

also can be fitted with RFID chips, and the resulting<br />

system “machine tool - fixturing - grinding wheel - dressing<br />

tool” makes for a grinding process perfectly adapted<br />

to the highest quality requirement both in accuracy and<br />

in short cycle times. The RFID option allows the tracking<br />

of the number of fixturing operations, the monitoring of<br />

maximum and minimum clamping pressures, and the integration<br />

of preventive maintenance. Furthermore, for a<br />

known part, the part data stored in the clamping tool can<br />

assist the machine tool in moving automatically into the<br />

correct set-up positions.<br />

6-Diamond dressing tool with RFID ring<br />

7-Clamping arbor with integrated RFID-chip<br />

Radio Frequency Identification (RFID) built into dressing<br />

tools serves, among other things, to generate and utilize<br />

usage data. The number of potentially remaining dressing<br />

cycles is stored in the dressing tool and can be read and accounted<br />

for by the machine. This offers the end-users an<br />

overview of the potential remaining dressing life, allowing<br />

stock management and determining when new <strong>tooling</strong><br />

should be ordered. Furthermore, the RFID chip also<br />

stores all the geometrical data of the dressing tool, which<br />

is directly read by the machine. For these reasons, input<br />

data errors are eradicated. Additionally, the end-users<br />

can choose from further options such as connections to<br />

internal and external <strong>tooling</strong> databases.<br />

Work Holding<br />

Precision gear grinding results depend on fixturing of<br />

equal high precision, which only hydraulic expansion can<br />

deliver with a repeatability of ≤ 3 micrometers. To maintain<br />

control over the whole gear-grinding process, Reishauer<br />

decided to make its own fixturing. The clamping tools<br />

are tailor-made to specific parts. The hydraulic expansion<br />

mandrels can be coupled to quick-change bases if a<br />

Made in Switzerland<br />

The high degree of in-house manufacturing or vertical integration<br />

is the foundation of the Reishauer performance<br />

portfolio. All core components are developed in-house and<br />

manufactured in Switzerland. In this way, the continuous<br />

generating process holds its leading-edge as the superior<br />

hard-finishing method for making gears.<br />

author:<br />

Walter Graf, Marketing<br />

Manager Reishauer AG, Switzerland.<br />

GrindTec <strong>2020</strong>, hall 3, booth 3017<br />

further information: www.reishauer.com<br />

8 no. 1, <strong>2020</strong>, March

materials & tools<br />

Pushing forward boundaries of<br />

additive manufacturing with new<br />

metal powders and components<br />

Sandvik and BEAMIT joined forces at Formnext<br />

2019 in Frankfurt to showcase the strength of<br />

the two companies’ combined offering in metal<br />

powder and additive manufacturing. Together the<br />

companies have leading capabilities across the<br />

whole additive manufacturing value chain, from<br />

metal powders to finished components.<br />

Earlier in 2019, Sandvik acquired a significant stake in<br />

BEAMIT - a leading European additive manufacturing<br />

(AM) service provider. The joint Sandvik-BEAMIT booth<br />

at Formnext featured several industrial additive customer<br />

use-cases in a wide range of materials, produced via different<br />

additive processes - along with Sandvik’s wide range of<br />

Osprey ® metal powders, now also including nickel-based<br />

superalloys and titanium. These high-grade powders can<br />

be used to produce light, but extremely durable components,<br />

with some incredible internal geometries that maximize<br />

their performance characteristics, making them suitable<br />

for use in demanding industries such as aerospace,<br />

automotive and energy. With these additions to the material<br />

program, Sandvik now offers one of the widest alloy<br />

programs on the market for additive manufacturing. In<br />

addition, the company’s additive machine park includes<br />

all relevant additive manufacturing processes for metals -<br />

meaning that Sandvik can tailor the powder to any printing<br />

process.<br />

High-profile 3D-printed components<br />

The Sandvik-BEAMIT booth featured some high-profile<br />

3D-printed components which underline the tremendous<br />

pace of technological advancement in the additive manufacturing<br />

sector. These include the world’s first 3D-printed<br />

diamond composite. This super-hard material is produced<br />

using an advanced proprietary Sandvik-process, printing<br />

in a slurry consisting of diamond powder and polymer,<br />

using a method called stereolithography, where complex<br />

parts are produced, layer by layer, using ultraviolet<br />

light. A tailor-made, post-processing method then makes it<br />

possible to achieve the exact properties of the super-hard<br />

diamond composite.<br />

“Until now, the production of super-hard diamond materials<br />

has only allowed for a few simple geometric configurations<br />

to be formed. But the new process means it<br />

is now possible to 3D-print diamond composites into almost<br />

any shape, which can revolutionize the way industries<br />

use the hardest natural material on the planet”, says<br />

Mikael Schuisky, VP and head of R&D and operations,<br />

Sandvik Additive Manufacturing. Another innovation on<br />

display at Formnext 2019 was the world’s first 3D-printed,<br />

smash-proof guitar (in titanium, of course), tested by rock<br />

legend Yngwie Malmsteen, and produced earlier this year<br />

as a means of showcasing the highly precise and amazing<br />

durable nature of the additive manufacturing process - and<br />

the strength of titanium.<br />

Revolutionizing milling cutter in titanium and<br />

3D-printed parts in super duplex<br />

Another innovation on display from Sandvik is the 3Dprinted<br />

lightweight CoroMill ® 390 titanium milling cutter,<br />

which is produced through additive manufacturing,<br />

reducing its weight by 80 % and increasing its productivity<br />

by up to 200 %. Sandvik has also produced 3D-printed<br />

parts in super duplex steel Osprey ® 2507-AM, with hardness<br />

and corrosion resistance properties that make them ideal<br />

for the harsh conditions encountered in the offshore and<br />

marine industries.<br />

Yngwie Malmsteen testing the<br />

3D-print smash-proof titanium guitar<br />

information: www.additive.sandvik<br />

no. 1, <strong>2020</strong>, March<br />


materials & tools<br />

Creating stator bores in a single operation<br />

Powerful tools for electric motor production<br />

The position of the automotive<br />

industry is clear. Over the<br />

next ten years practically every<br />

car maker will be building electric<br />

cars by the million - with<br />

clean electric motors and as<br />

plug- in hybrids. However, the<br />

question remains: are the right<br />

tools available for the large-scale<br />

production of electric motors?<br />

At EMO 2019, CERATIZIT<br />

demon strated an extremely effective<br />

tool programme that provides<br />

the perfect technical and<br />

commercial solution for every<br />

ma chining task encountered in<br />

the production of electric motors.<br />

The two newly developed<br />

fine boring tools for the hig<strong>hp</strong>erformance<br />

high volume production<br />

of electric motor housings<br />

are simply outstanding.<br />

Present situation<br />

The machining demands represented<br />

by the housing of a car’s electric<br />

motor are no different from those of<br />

an internal combustion engine, apart<br />

from the stator bore of the thin-walled<br />

electric motor housing. Depending on<br />

the size and type of the motor, the<br />

stator bore will vary between approximately<br />

Ø 200 mm and 300 mm, extend<br />

to a depth of more than 300 mm<br />

and must satisfy extremely tight accuracy<br />

requirements; for example, tolerances<br />

conforming to IT6 and roundness<br />

criteria as low as 2/100 mm.<br />

These are huge challenges for a finishing<br />

tool designed to produce the<br />

complete bore in a single operation<br />

in high volume production. However,<br />

they have to be met if electric motors<br />

are to be produced in a timely and<br />

economic manner in quantities in excess<br />

of 100,000.<br />

Solid steel tools are ill-equipped for<br />

these tasks, as they are far too heavy<br />

for most machine spindles. The solution<br />

is to be found in lightweight<br />

bodies that reduce the tool weight to<br />

somewhere below 20 kg, which today’s<br />

standard CNC machining centres are<br />

able to accommodate. Available in<br />

multi-step designs for complete machining<br />

applications, they feature<br />

several cutting edges per step and in<br />

some cases guide rails as well. Despite<br />

their light weight, fine boring tools<br />

like these must possess a high degree<br />

of rigidity to successfully transmit the<br />

power to the cutting edges and hence<br />

achieve the required tolerance results<br />

Additively manufactured<br />

high-end solution<br />

With its new fine boring tool, which<br />

is additively manufactured throughout,<br />

CERATIZIT has developed a special<br />

tool for stator bores that satisfies<br />

all the stipulated requirements and<br />

leaves nothing to be desired in terms<br />

of machining speed and precision.<br />

The totally new design makes it rigid<br />

enough to satisfy IT6 tolerance requirements<br />

and the corresponding<br />

roundness criteria.<br />

Despite its large diameter (in excess<br />

of 200 mm) and considerable length,<br />

the developers have managed to keep<br />

the weight of the fine boring tool below<br />

17 kg and designed it to accommodate<br />

the tilting moment of machining<br />

centres. That such a lightweight<br />

tool can be manufactured at<br />

all is down to the experience in 3D<br />

printing gained over the years by<br />

CERATIZIT. The delicate, optimally<br />

braced structure of the base body can<br />

only be produced by an additive manufacturing<br />

(AM) process. Experienced<br />

AM designers, who are not only aware<br />

of the potential offered by generative<br />

manufacturing but are also familiar<br />

with the requirements of 3D printing,<br />

have used FEM calculations to investigate<br />

the effective forces and optimise<br />

Produce stator bores at unbelievable<br />

levels of efficiency; with the new<br />

special tool from CERATIZIT<br />

that will soon be possible<br />

the topology of the structure. The result<br />

is a fine boring tool whose design<br />

can be scaled almost at will to meet a<br />

customer’s needs. With four cutting<br />

edges per step and up to five steps per<br />

tool, even challenging boring tasks<br />

can be completed at high feed rates in<br />

a single operation.<br />

Effective plug & play solution<br />

The PCD cutting edges are soldered<br />

into cartridges that are also additively<br />

manufactured. This eliminates any<br />

heat input into the base body and<br />

prevents the associated deformation.<br />

Once the loaded cartridges have been<br />

fitted into the designated fixtures in<br />

the base body, CERATIZIT grinds the<br />

tool to precisely the required size -<br />

10 no. 1, <strong>2020</strong>, March

materials & tools<br />

with micrometre precision. Customers obtain a plug & play<br />

solution that will enable them to achieve process-secure<br />

machining results that are always within specification.<br />

By using 3D printing, CERATIZIT was able to take advantage<br />

of other strengths of the additive manufacturing process.<br />

The coolant holes in both the base body and the cartridges<br />

are designed such that every cutting edge receives<br />

exactly the amount of coolant it needs while at the same<br />

time flushing the chips out of the bore. Scratched surfaces<br />

are avoided, which contributes greatly to increased process<br />

security and a reduction in waste.<br />

it’s no less innovative. It is more affordable and of a modular<br />

design that makes it easier to manufacture.<br />

Lightweight construction and the AM expertise at<br />

CERATIZIT were also to the fore in this new development.<br />

The CERATIZIT branch in Stuttgart-Vaihingen is responsible<br />

for the individual design of the fine boring tool with<br />

regard to tool size, guide rails and the required number of<br />

steps. It is also where the tools are manufactured on an<br />

ultra-modern machine.<br />

The advantages at a glance:<br />

➤ complete finish machining of the stator bore<br />

in a single operation<br />

➤ up to five steps, each with four PCD cutting edges,<br />

offers high-performance capability<br />

➤ extremely precise machining results<br />

(tolerance class IT6)<br />

➤ topology-optimised, additively manufactured<br />

lightweight body<br />

➤ additively manufactured tool cartridges with<br />

soldered PCD cutting edges<br />

➤ optimised coolant hole configuration for cooling<br />

each cutting edge and flushing chips out of the bore<br />

➤ customer-specific design<br />

Plastic step boring bar for the stator bore<br />

CERATIZIT has developed another fine boring tool for the<br />

electric motor housing. Its design is somewhat simpler, but<br />

Thanks to its incredibly innovative design, the weight of the<br />

tool is reduced to well below what the market has come to<br />

expect and is consequently exactly what anyone involved<br />

in the machining of stator bores in a single operation<br />

on machining centres has been waiting for<br />


Schleifscheibenfabrik GmbH & Co. KG<br />

• CBN and Diamond Wheels in Vitrified Bond<br />

• Grinding Wheels in Vitrified Bond<br />

• Grinding Wheels in Resinoid Bond<br />

• Fiber-reinforced Cut-off and Rough Grinding Wheels<br />

Innovative Grinding Technology since 1895!<br />

Visit us:<br />

Hall 2<br />

Stand 2031<br />

18 - 21 March <strong>2020</strong><br />

Augsburg<br />

Grinding Perfection for<br />

every Process!<br />


Schleifscheibenfabrik GmbH & Co. KG<br />

Bremer Str. 44 • 34385 Bad Karlshafen<br />

Phone: +49 5672 184-0<br />

E-Mail: mail@krebs-riedel.de<br />

Web: www.krebs-riedel.de<br />


materials & tools<br />

The plastic step boring bar consists of<br />

a tubular lightweight base body that<br />

is made using conventional cutting<br />

pro cesses. The diameters of the stator<br />

bore are fashioned using additively<br />

manufactured steps containing cartridges<br />

equipped with PCD or indexable<br />

inserts.<br />

Carbon-fibre reinforced<br />

special plastic<br />

These steps are the absolute highlight<br />

of the tool, as they are created additively<br />

using a special plastic developed<br />

by CERATIZIT. The high degree<br />

of rigidity of the plastic is due to the<br />

integrated additional materials. Having<br />

been optimised topologically during<br />

the development, they are, despite<br />

their minimal weight, able to divert<br />

the machining forces generated<br />

into the base body. The special plastic<br />

is also vibration-damped, while the<br />

3D printing method allows the coolant<br />

holes to be configured as required.<br />

The coolant can therefore be channelled<br />

in the best way to flush the<br />

chips to the rear and out of the hole.<br />

The cartridges for each step are<br />

equipped with PCD cutting edges or<br />

indexable inserts. Not a standard tool<br />

holder, but a design that prevents<br />

the tightening torque of the indexable<br />

insert from acting on the plastic.<br />

The cartridge also has an electronic<br />

component that enables fine adjustments<br />

to be carried out digitally on<br />

the indexable insert. A display can<br />

be docked via a digital interface and<br />

cutter adjustments then performed to<br />

micrometre-level precision.<br />

Modular design<br />

The modular design featuring base<br />

body and steps allows the light-weight<br />

counterboring tool to be configured as<br />

a multi-step tool entirely to a customer’s<br />

requirements to facili tate the complete<br />

machining of the stator bore in a<br />

single operation. Additional enhancements<br />

to hold an additional tool on<br />

the front, e.g. for the rotor shaft bearing,<br />

are under consideration.<br />

Available quickly<br />

Customers will love the fact that<br />

the delivery period is so short, even<br />

though everything’s made to measure.<br />

CERATIZIT holds the base body<br />

as a semi-finished product in stock -<br />

The new design and forming fixture of the high-end boring tool<br />

is printed entirely from steel<br />

with a flexible KOMET ABS or HSK<br />

interface. The plastic steps are produced<br />

very quickly on a 3D printer.<br />

Without having to wait too long, the<br />

customer therefore receives a tool that<br />

can be used to machine stator holes<br />

with previously unattainable levels of<br />

efficiency.<br />

The advantages at a glance:<br />

➤ flexible machining of stator bore<br />

to customer’s specification;<br />

for rough machining, finish<br />

machining or a combination<br />

of both<br />

➤ facility for additional tools<br />

possible<br />

➤ extremely precise machining<br />

results (tolerance class IT6)<br />

➤ modular tool design<br />

➤ topology-optimised, additively<br />

manufactured plastic steps<br />

➤ digitally adjustable tool cartridges<br />

can be fitted<br />

➤ optimised coolant channelling<br />

for flushing chips out of the bore<br />

➤ short delivery times<br />

Tools with intelligence<br />

CERATIZIT has always made the availa<br />

bility of digital support for its users a<br />

priority. KOMET KOMlife, the newly<br />

developed digital maintenance indicator,<br />

is a helpful add-on that further<br />

increases process security. KOMET<br />

KOMlife can be fitted to the two new<br />

fine boring tools as well as any rotating<br />

tool with a diameter of 50 mm<br />

and above.<br />

With its KOMlife predictive maintenance<br />

system, CERATIZIT has set another<br />

milestone in the development of<br />

innovative maintenance strategies.<br />

KOMlife allows operational data to<br />

be recorded directly on the tool itself<br />

and displayed on an integrated display,<br />

which is activated using a magnetic<br />

stylus. The maintenance indicator<br />

can be adapted to a customer’s specific<br />

needs - such as when to change<br />

a cutting edge - using the adjustable<br />

maintenance interval. If the interval<br />

is exceeded, a flashing red LED indicates<br />

that maintenance is overdue. To<br />

acquire operational data digitally, the<br />

recorded data can be retrieved by the<br />

KOMlife app using the dynamic and<br />

patented QR code.<br />

The advantages at a glance:<br />

➤ low-cost, digital maintenance<br />

indicator<br />

➤ autonomous data acquisition<br />

on the tool itself<br />

➤ integrated display<br />

➤ dynamic QR code - can be read<br />

using KOMlife app<br />

➤ for all rotating tools with<br />

diameters of 50 mm and above<br />

12 no. 1, <strong>2020</strong>, March

materials & tools<br />

Ingenious combination of measuring probes<br />

and spindle head<br />

Another new CERATIZIT tool is making waves in motor<br />

machining (and elsewhere): the KOMET MicroKom<br />

KOMflex spindle head, which is designed for the precise<br />

machining of bearing seats and cylinder bores, enables<br />

CERATIZIT to fill the gap between manual spindle tools<br />

and the flexible U-axis systems.<br />

The KOMflex is extremely compact and uses the radio<br />

technology of a measuring probe to intelligently<br />

produce bores with self-correction (cutting edge compensation).<br />

This combination of measuring probe and<br />

spindle head in a single system is unique, offering the<br />

customer both technological and financial advantages.<br />

The precision spindle system works completely independently.<br />

All you need to use for this tool is a machine<br />

with a built-in radio receiver so that the KOMflex spindle<br />

head and measuring probe can be controlled. The<br />

spindle head can also be manually controlled and adjusted<br />

via the machine control system or a magnetic<br />

switch located on the head itself. The KOMflex operates<br />

at speeds of up to 8,000 rpm and ensures positional<br />

accuracy to 0.001 mm.<br />

2 O 2 O<br />

The new boring tool from CERATIZIT has multiple steps<br />

to enable the entire stator bore to be completely machined<br />

in a single operation<br />

Please visit us at Hall 5, Booth 5077<br />

The advantages at a glance:<br />

➤ precise machining of bearing seats and<br />

cylinder bores<br />

➤ combination of measuring probe and spindle head<br />

➤ compact design<br />

➤ radio technology for intelligent cutter<br />

compensation<br />

➤ speeds of up to 8,000 rpm<br />

➤ adjustable to within 0.001 mm<br />

GrindTec <strong>2020</strong>, hall 5, booth 5005<br />

information: www.ceratizit.com<br />

14 - 17 March 2018<br />

Messe Augsburg<br />

18 - 21 March <strong>2020</strong><br />

Messe Augsburg<br />


materials & tools<br />

Reliable, cost effective serial production<br />

of turbochargers<br />

Offer for the complete process<br />

The turbocharger has been<br />

state-of-the-art in diesel vehicles<br />

for some time. And almost all<br />

automotive manufacturers offer<br />

a turbocharged petrol engine.<br />

Why? The turbocharger makes<br />

comparable performance with a<br />

smaller engine capacity possible<br />

and that contributes to the advance<br />

in downsizing.<br />

Turbochargers also help to<br />

achieve lower fuel consumption<br />

and are therefore fundamental<br />

in meeting strict emission limits.<br />

MAPAL offers the complete process<br />

for machining these parts,<br />

including tools.<br />

Challenge for machining tools<br />

Most turbochargers are exhaust gas<br />

turbochargers. These look different<br />

at almost every automotive manufacturer<br />

and have a special geometry.<br />

Common to all: there are very high<br />

temperatures when they are used in<br />

vehicles with petrol engines. For this<br />

reason the turbine housing, the socalled<br />

“hot side” is manufactured<br />

from very abrasive, heat-resistant materials.<br />

These materials represent a<br />

par ticular challenge for every machining<br />

tool.<br />

Complex boring tool with<br />

ISO indexable inserts<br />

MAPAL has taken up these challenges<br />

and developed new cutting materials<br />

and tools. The company offers the<br />

com plete process for machining turbo<br />

chargers, including all tools, for example<br />

drills, milling cutters, reamers<br />

and mechatronic actuating tools -<br />

matched to the related geometry of<br />

the turbocharger. The company also<br />

assists its customers during the continuous<br />

further development of processes,<br />

to reduce cycle times and to<br />

increase tool lives. As such, combination<br />

tools that undertake multiple machining<br />

operations in one machining<br />

step form part of the portfolio.<br />

Turning on the machining centre<br />

using TOOLTRONIC<br />

A large part of turbocharger machining<br />

can be implemented using<br />

tools with ISO indexable inserts. Including<br />

many machining processes<br />

on the challenging hot side. MAPAL<br />

has developed a cutting material specially<br />

matched to the machining of<br />

heat- resistant cast steel and that offers<br />

long tool lives and therefore high<br />

cost-effec tiveness, despite the abrasiveness<br />

of the material.<br />

1. Complex boring tool with<br />

ISO indexable inserts<br />

It is necessary to machine the V band<br />

on every turbocharger. Along with the<br />

material properties, an interrupted<br />

cut is often a challenge here during<br />

pre-machining. MAPAL relies on a<br />

com plex boring tool with ISO indexable<br />

inserts to pre-machine the V<br />

band as well as to pre-machine the internal<br />

contour of the turbine. The tool<br />

therefore machines internally and externally<br />

simultaneously. Multiple steps<br />

are machined. The tool operates counter-clockwise<br />

to transport the chips<br />

out of the component and to prevent<br />

damage to the internal contour of the<br />

turbine.<br />

machining example:<br />

New face milling cutters<br />

for roughing<br />

material: 1.4837<br />

cooling: MQL<br />

diameter: 49; 70.5; 73; 90 mm;<br />

chamfer 10°<br />

cutting speed: 70 m/min<br />

feed: 0.4 mm<br />

tool life: 75 parts<br />

14 no. 1, <strong>2020</strong>, March

materials & tools<br />

2. Turning on the machining<br />

centre using TOOLTRONIC<br />

A particular challenge during the machining<br />

of the turbine housing for<br />

exhaust gas turbochargers is the main<br />

turbine bore. Its manufacture is subject<br />

to close tolerances in relation to<br />

shape, position and surface finish. The<br />

bore is bell-mouthed shaped to generate<br />

the best possible flow characteristics.<br />

MAPAL undertakes this machining<br />

operation using TOOLTRONIC<br />

with the LAT attachment (linear actua -<br />

ting tool). TOOLTRONIC, a mechatronic<br />

tool system, is a full NC axis<br />

integrated into the existing machine<br />

controller. The mounting tool is fitted<br />

with three inserts, one for roughing<br />

and two for finishing.<br />

machining example:<br />

material: 1.4837<br />

cooling: MQL<br />

diameter: 40.5 - 57.295 mm<br />

cutting speed: 140 m/min (roughing),<br />

120 m/min (finishing)<br />

feed: 0.15 - 0.4 mm<br />

tool life: 50 parts<br />

3. New face milling cutters<br />

for roughing<br />

MAPAL recently announced a milling<br />

range with pressed, radial ISO indexable<br />

inserts. The milling cutter for<br />

roughing the face surface on the turbocharger<br />

housing comes from this<br />

range. The ISO indexable inserts with<br />

16 usable cutting edges are the highlight<br />

of this face milling cutter. As<br />

such the usage of the tool is particularly<br />

economical.<br />

machining example:<br />

material: 1.4849<br />

cooling: dry machining<br />

diameter: 125 mm, 14 inserts<br />

cutting speed: 80 m/min<br />

feed: 0.12 mm<br />

tool life: 125 parts<br />

4. Diameter turning tool with<br />

tangential technology<br />

The new tool from MAPAL for pre-machining<br />

the catalytic converter flange<br />

is also particularly cost-effective. Tangential<br />

technology is used on this diameter<br />

turning tool. Due to the upright<br />

and horizontal installation of<br />

the LTHU inserts, in effect eight cutting<br />

edges can be used per indexable insert.<br />

machining example:<br />

material: 1.4837<br />

cooling: MQL<br />

diameter: 119 mm<br />

cutting speed: 80 m/min<br />

feed: 0.3 mm<br />

tool life: 100 parts<br />

Diameter turning tool with<br />

tangential technology<br />

The four tools mentioned demonstrate<br />

on the one hand the different<br />

machining tasks on a turbocharger<br />

and on the other hand symbolise<br />

the variety of tools and know-how<br />

available from MAPAL. From standard<br />

mil ling cutters, through mechatronic<br />

actuating tools, to complex boring<br />

tools, the programme includes all<br />

the tools necessary for machining turbochargers,<br />

including the tool clamping<br />

systems. MAPAL designs the complete<br />

machining process such that the<br />

most reliable and cost-effective strategy<br />

for the customer is used. There<br />

is always a close eye on accuracy<br />

down to the μm so that the turbochargers<br />

achieve the highest possible<br />

efficiency in operation.<br />

MAPAL offers the complete process for machining turbochargers<br />

information: www.mapal.com<br />

no. 1, <strong>2020</strong>, March<br />


materials & tools<br />

50 years Borazon -<br />

CBN grinding wheels<br />

… and another anniversary<br />

for pioneer LACH DIAMANT<br />

In 1969, during the spring tradefair in Hanover, LACH DIAMANT<br />

was the first manufacturer worldwide to demonstrate the grinding of<br />

HSS and high-alloy steel on a tool grinding machine. The experts were<br />

amazed - because it was the first time they saw HSS (high speed steel)<br />

chips «produced» during grinding…<br />

First Borazon/CBN presentation stand<br />

at the spring tradefair in Hanover in 1969<br />

( General Electric)<br />

At the same time, the first CBN grinding<br />

wheel for dry grinding of an HSS milling<br />

cutter had its premiere. These were the beginnings<br />

of LACH DIAMANT’s grinding<br />

wheels first known as Borazon - a trademark<br />

of General Electrics, at that time a<br />

manufacturer of super-abrasives: K-MX for<br />

resinoid bonds, Bz-Mx for metal bonds.<br />

«Start with Borazon» - NASA gave<br />

permission to use the «moon spider»,<br />

visible in the background of the picture,<br />

for advertising<br />

Today with a view to the international<br />

GrindTec tradeshow in Augsburg, from<br />

March 18th to 21st, <strong>2020</strong>, LACH DIAMANT<br />

offers a proven selection of conventional<br />

diamond dressing tools, dressing rolls<br />

and diamond and CBN grinding wheels as<br />

well as trendsetting<br />

developments<br />

which were in recent<br />

years advertised<br />

under the<br />

slogan «Future for<br />

Today».<br />

After 50 years of<br />

Borazon - originally<br />

advertised as<br />

the abrasive of a<br />

new era - the unchallenged culmination of success was<br />

the metal-bond profile grinding wheel «contour-profiled»<br />

- a time and cost killer for production grinding of highalloyed<br />

steel, regarding profiles.<br />

Revolutionary deep grinding with<br />

«contour-profiled», metal-bond diamond<br />

and CBN profile grinding wheels –<br />

showing a CBN grinding wheel<br />

(Ø 400 mm) on a mini «contour-profiled»<br />

spark grinding machine EDG-plus<br />

To date, LACH DIAMANT has not only solved unimaginable<br />

grinding tasks, but has also developed a special<br />

electrical discharge (EDG) profiling machine for regrinding<br />

even the most precise concave and convex profiles of<br />

2-4 µ. It is available for service and for resale.<br />

GrindTec <strong>2020</strong>, hall 1, booth 1076<br />

Featuring the «miracle machine» - the «contour-profiled»<br />

spark grinding machine EGD-plus by LACH DIAMANT<br />

information: www.lach-diamant.de<br />

16 no. 1, <strong>2020</strong>, March

materials & tools<br />

Meet the experts<br />

Meet the experts of Meister Abrasives and Alfons Schmeier<br />

Abrasives showcasing their <strong>2020</strong> high performance grinding wheel<br />

innovations at GrindTec, Augsburg. The group is known for its best<br />

product performance following the vision revolutionizing grinding<br />

technology. Key to sustainable, innovative solutions are 100 %<br />

customer focus, technical experts and the competent world wide<br />

distribution network.<br />

This year’s key technology innovations<br />

are the world’s first Vitrified Micron<br />

(VM) for extremely fine surfaces, HPL for<br />

maxi mum removal rate and hDD 2.0 for<br />

highest productivity.<br />

Daily technical forum presentations on this<br />

year’s innovations will be held at the booth<br />

at 10:30 h, 13:30 h and 16 h.<br />

Tools cut better<br />

with TIGRA<br />

PCD<br />

PcBN<br />

Tungsten Carbide<br />

GrindTec <strong>2020</strong>, hall 3, booth 3070<br />

VM micro structure<br />

for extremely fine surfaces<br />

Customised<br />

preforms<br />

PCD and PcBN in<br />

blanks and segments<br />

HPL technology for max. removal rate<br />

Carbide rods<br />

and milling cutter<br />

blanks<br />

Carbide inserts for<br />

tipping with PCD<br />

hDD 2.0 technology<br />

for highest productivity<br />

information: www.meister-abrasives.com<br />

We´ll be there!<br />

Hall 5-5036<br />

TIGRA GmbH<br />

Gewerbering 2<br />

D-86698 Oberndorf am Lech<br />

Germany<br />

Tel +49 (0)9090 9680-01<br />

Fax +49 (0)9090 9680-50<br />

sales@tigra.de<br />


materials & tools<br />

Efficiency = saving time while increasing<br />

precision and quality<br />

Medical screws<br />

A drill, a milling cutter, an ultimate machining<br />

strategy with perfectly tuned parameters; this<br />

is needed, when machining medical screws made<br />

from titanium or stainless steels. Mikron Tool<br />

developed a turn-key solution, which simultaneously<br />

does the machining of hex lobular bone<br />

screws (better known as Torx ® ) 50 % faster, guaranteeing<br />

also a high degree of precision of the<br />

profile and achieving nearly burr-free results.<br />

With an increasing tendency, yearly 900 million medical<br />

screws are produced. Each second which can be gained in<br />

the process counts. Most of these screws are produced on<br />

lathe machines, on the main spindle the thread and on<br />

the sub-spindle the hexalobular Torx ® socket is machined.<br />

That particular operation is usually slower and defines the<br />

cycle time. Here is an opportunity to improve the efficiency,<br />

all be it by only a few seconds. Nevertheless it saves<br />

the manufacturer time and money.<br />

Mikron Tool offers with the HEXALOBE-Program a turn<br />

key solution, which is not only based on the cutting tools,<br />

but also delivers a package with the best machining strategy<br />

and the right parameters. Because during the development<br />

of the program it became quite clear that good<br />

results can only be obtained when all factors fall in place<br />

correctly.<br />

Titanium or stainless steels?<br />

The two materials with which today 90 % of all medical<br />

screws are made are titanium and stainless steels. These<br />

are quite different when it comes to their behavior during<br />

the chip removal process. Such that during the development<br />

it became clear that the tools as well as the suitable<br />

strategy needed a differentiation. Especially with titanium<br />

with its high elasticity stronger cutting force was required,<br />

which in turn produced higher stress on the cutting edges.<br />

This already meant right from the beginning of the development,<br />

that a different carbide was called for.<br />

For the machining process, both materials have to be<br />

differentiated. While with titanium the helical interpolation<br />

and also side milling are possible, Mikron Tool only<br />

recom mends side milling when working with stainless<br />

steels. Even though this particular process is a bit more<br />

time consuming.<br />

The strategy<br />

A well-defined strategy was just as important as the cutting<br />

tools when development was initiated. Because when choo s -<br />

ing the tools it must be clear how these are being applied.<br />

Right from the beginning different approaches were considered.<br />

Especially efficient turned out to be the one which<br />

could do with a minimum of different tools i.e. stepdrilling<br />

- milling the hexalobe - subsequent deburring. Other<br />

strategies like predrilling of the six exterior diameters and<br />

the center with the following milling and deburring were<br />

a challenge, especially when working with Titanium. It<br />

turned out to be a demanding task for the micro drills.<br />

The milling process, in the chosen strategy the most<br />

time consuming operation,<br />

can be done with<br />

helical interpolation<br />

(with max. pitch 0.8 x d)<br />

or with side milling<br />

(with step over max.<br />

0.5 x d). Each procedure<br />

has its pros and cons:<br />

with helical interpolation<br />

there will be a<br />

slight lateral load at the<br />

milling cutter (Fx), since<br />

there is also a simultaneous<br />

vertical stress<br />

(Fz).<br />

Screws<br />

Torx ® socket<br />

A higher stress on the<br />

cutting edge corners has<br />

to be reckoned with and<br />

because of this they<br />

were geometrically rein<br />

forced. Generally this<br />

18 no. 1, <strong>2020</strong>, March

materials & tools<br />

Helical interpolation - side milling<br />

Cutting tools (combined drill and milling cutter)<br />

produces a faster and more fluid operation. With the side<br />

milling (or wall milling) the total depth is reached in<br />

several steps, since only two axes are used for each step.<br />

The step-over stays the same for the entire operation even<br />

though the radial stress on the cutter is more elevated.<br />

Reduce four to two<br />

The four operations (pre-hole drilling - chamfering - milling<br />

- deburring) need to be completed in three operations<br />

with two tools. First a step drill does the center bore and a<br />

chamfer of 120° and this right away with an excellent surface<br />

quality of Ra 0.2 um, Rz 0.8 um. After the milling of<br />

the final shape, this tool will be used once again in the last<br />

operation to achieve a nearly burr-free surface and superior<br />

surface quality. The milling cutter with 3 or 4 flutes - depending<br />

on diameter - is available in two standard lengths,<br />

so that depending of the screw type, different Torx shapes<br />

can be machined. It’s high stiffness allows machining<br />

with high feeds and massive stepover, while still guaranteeing<br />

the necessary hexalobular profile accuracy. The surface<br />

quality is given by the special geometry which also affords<br />

to work with high stepover so that the operation can<br />

be completed with few steps.<br />

First experiences with the new CrazyDrill und Crazy-<br />

Mill Hexalobe tools on a lathe machine 32/8 from DMG<br />

MORI have shown, that cycle time compared to other<br />

on the market available tools could be reduced by 50 to<br />

60 % while at the same time with a fast feed (0.03 mm/rev.<br />

per flute) and high surface quality (Ra = 0.2 um) can be<br />

reached. A quite promising result!<br />


kapp-niles.com<br />

information: www.mikron.com<br />

Focus on Quality<br />

Besides efficient machining, which means short cycle time<br />

and long tool-life, the development of the new tools concentrated<br />

also on achieving top quality. Very tight tolerances<br />

must be kept to guarantee profile accuracy and wall<br />

squareness of the hexalobular socket, and this from the<br />

first to the last screw produced.<br />

Profile accuracy<br />

Obviously the surface quality and burr condition are also<br />

an important topic. The head of development, Alberto<br />

Gotti, confirms that there is no “perfect solution for all<br />

cases”.<br />

Even though, this turn-key program with a combination<br />

of cutting tools, recommendations for the strategy and<br />

parameters gives the end-user excellent support, he still<br />

challenged to find “his” balance between most efficient<br />

machining, high precision and quality.<br />

GrindTec <strong>2020</strong><br />

18 - 21 March<br />

Messe Augsburg | Germany<br />

Hall 3 | Booth 3001

materials & tools<br />

Round geometry<br />

Round inserts promote better profiling with<br />

long overhangs in narrow grooves 10-26<br />

Cutting tool and <strong>tooling</strong> system specialist<br />

Sandvik Coromant is adding round geometry<br />

(-RM) inserts to its programme of CoroCut ® QD<br />

parting off and grooving tools. Round geometry<br />

allows profiling with long overhangs in narrow<br />

grooves, while further applications include external<br />

profiling, the generation of recesses and undercuts,<br />

and the potential to use non-linear turning<br />

and grooving with a full radial bottom.<br />

“The features and benefits of using round geometry inserts<br />

with CoroCut ® QD holders include better tool life and chip<br />

control with a rigid insert seat, internal over- and undercoolant<br />

for improved process security and chip evacuation,<br />

and the potential for use with a Y-axis blade,” explains Dr.<br />

Angélica González, Global Product Manager -<br />

Turning tools at Sandvik Coromant.<br />

CoroCut ® QD-RM with blade<br />

A customer case example ably demonstrates the potential<br />

gains on offer. A shaft made from 42CrMo4 alloy<br />

steel required grooving operations on a Niles- Simmons<br />

N30 CNC lathe. Using a CoroCut ® QD holder with -RM<br />

geo metry inserts in place of a competitor solution saw tool<br />

life doubled with far better chip control. The cutting data<br />

was identical for both tools:<br />

290 rpm spindle speed;<br />

160-180 m/min (525-591 ft/min) cutting speed;<br />

0.3 mm/rev (0.012 in/rev) feed rate;<br />

and 2.7 mm (0.079 in) axial depth of cut.<br />

Three grades are available for the inserts. GC1125 grade<br />

is ideal for finishing in all materials, as well as certain<br />

roughing operations in non-ferrous metals, heat-resistant<br />

super alloys (HRSAs) and titanium, while GC1135 grade is<br />

first choice for roughing in stainless steel and HRSAs. Also<br />

offered is GC4335 grade for roughing steel and cast-iron<br />

workpieces.<br />

The assortment is available in four insert sizes of<br />

3, 4, 6 and 8 mm (0.008, 0.157, 0.236 and 0.315 inch).<br />

CoroCut ® QD-RM geometry<br />

information: www.sandvik.coromant.com<br />

20 no. 1, <strong>2020</strong>, March

Partner for carbide rods<br />

and special solutions<br />

materials & tools<br />

Boehlerit is a true pioneer in the development<br />

of cutting materials from carbide and a European<br />

premium manufacturer whose outstanding expertise<br />

results from its close links with the steel industry.<br />

The result: high-end grade solutions for<br />

ro ta ting carbide tools that are suitable for a wide<br />

range of applications.<br />

The Kapfenberg-based tool manufacturer looks back on<br />

many years' experience with carbide blanks and semi-finished<br />

products for the precision tool industry and offers a<br />

multitude of special material grades with varying grain<br />

sizes. The micro-grain carbide grades HB10F, HB20F and<br />

HB30F were developed for the machining of non-ferrous<br />

metals, aluminium alloys, fibre-reinforced plastics, graphite,<br />

low- and medium-hard casting materials, chilled casting<br />

and hardened steels. Furthermore, Boehlerit offers two<br />

special grades in the micro-grain range with HB20UF and<br />

HB44UF. HB20UF is ideal for the pro cessing of composites<br />

as well as for HSC milling. HB44UF is used for all rotating<br />

tools within the field of HSC technology and for the machining<br />

of hardened steels up to 64 HRC.<br />

HB40T, a special carbide grade that was developed by<br />

Boehlerit, offers a combination of toughness and wear resistance<br />

that is ideal for the roughing of titanium. When it<br />

comes to mil ling titanium, its toughness poses a challenge<br />

for the cutting material used, as it leads to high temperatures<br />

and wear levels on the tool blade. To counteract this,<br />

tools require a sophisticated combination of metallic hard<br />

materials that<br />

have contradictory<br />

properties.<br />

Carbide grade<br />

HB40T offers an<br />

ideal combination<br />

of high<br />

wear resistance<br />

and toughness.<br />

Boehlerit offers<br />

the HB40T<br />

grade as a bar<br />

mate rial. These<br />

blanks are perfect<br />

for the ma nu facturing of shaft tools that are used for<br />

titanium roughing applications, for example. The HB40T<br />

is thus the starting point of choice for <strong>tooling</strong> applications<br />

in almost all industrial areas where titanium is processed.<br />

Typical areas of application include the processing of aeroplane<br />

structure parts or engine components, products in<br />

the medi cal technology sector or com po nents for chemical<br />

or energy plants.<br />

New in the Boehlerit portfolio is the extremely wearresistant,<br />

ultra-fine grain grade HB05UF, the ideal solution<br />

for the processing of abrasive compounds and materials in<br />

a hardness range of > 64 HRC.<br />

GrindTec <strong>2020</strong>, hall 2, booth 2095<br />

information: www.boehlerit.com<br />

«Solutions in new dimensions»<br />

Leitz will exibit at Holz-Handwerk <strong>2020</strong> in<br />

Nuremberg, March 18 to 21, <strong>2020</strong>. The world market<br />

leader from Oberkochen will be presenting<br />

service concepts, industry highlights and innovations<br />

and supplements to the range for the woodworking<br />

and wood-processing industries under<br />

the motto “Solutions in new dimensions”.<br />

Focus on regrinding - tools as new,<br />

in manufacturer quality<br />

One of the focal points will be the Leitz regrinding service.<br />

Over the past decades, Leitz has managed to establish an<br />

unrivalled level of customer proximity with its global network<br />

of highly qualified service stations and set the benchmark<br />

for perfect service. At the fair, Leitz will present service<br />

concepts that make it clear that reshapening and reconditioning<br />

tools in manufacturer quality is the only<br />

economic alternative to disposable products. Leitz sees itself<br />

as a partner of the trade, especially for small and medium-sized<br />

companies, with its logistics and consulting<br />

concept, which is operated exclusively with its own qualified<br />

experts from the industry<br />

and with guaranteed<br />

short delivery times.<br />

Leitz will also present its<br />

digital solutions such as<br />

the proven Leitz XPress-<br />

Button or the Leitz XPert<br />

solution concept.<br />

Focus on furniture<br />

production - when diversity meets individuality<br />

For the furniture industry, Leitz offers a tool solution for<br />

every conceivable challenge. Whether it be circular sawblades<br />

such as the RazorCut for perfect panel cutting, the<br />

Diamaster EdgeExpert shank cutter for perfect nesting or<br />

the new solid carbide hinge boring bit Z3/V3, which enables<br />

unrivalled perfect hole edges with the highest boring<br />

performance.<br />

HOLZ-HANDWERK <strong>2020</strong>, hall 10, booth 206<br />

information: www.leitz.org<br />

no. 1, <strong>2020</strong>, March<br />


materials & tools<br />

A wide product range<br />

Dressing tools and digital solutions<br />

KAPP NILES, as a manufacturer of gear and<br />

profile grinding machines, offers highly developed<br />

technologies with various tool concepts adapted<br />

to the respective task. The product range in<br />

the tool sector includes dressing tools for dressing<br />

vitri fied bonded grinding tools and non-dressable<br />

grinding tools with CBN- and diamond coating.<br />

Dressing tools can be used for the following processes:<br />

KAPP NILES offers dressing rolls in galvanic positive and<br />

nega tive versions for the generating grinding. These are<br />

used for flexible, workpiece-bonded or topological dressing<br />

of vitrified bonded corundum grinding worms.<br />

Diamond profile rolls with or without head dressing device<br />

For the profile grinding process KAPP NILES offers diamond<br />

form rolls in sintered design. In addition to the economical<br />

version with natural diamond, the durable version<br />

with set CVD diamond plates is also used. The diamond<br />

form rolls can be reground several times and are<br />

characterised by a long tool life.<br />

Diamond dressing gears are available for gear honing.<br />

These bring the correct tooth geometry quickly and accurately<br />

into the corresponding honing ring and guarantee<br />

the quality desired at the component.<br />

In addition to the dressing tools, CBN and diamond<br />

grinding tools have been part of the product range for over<br />

40 years. KAPP NILES manufactures non-dressable, electroplated<br />

single-layer CBN and diamond tools for finishing<br />

Multi-groove diamond full profile rolls<br />

of gears and profiles. The tools are characterised by long<br />

tool life, accuracy and regrindable bodies and are among<br />

the top products worldwide. They are used when the highest<br />

demands are placed on quality, performance and economy.<br />

The CBN coating can be renewed more than 50<br />

times, thus contributing to the conservation of resources.<br />

On request, tools can be equipped with RFID chips,<br />

which enables integration into a tool data management<br />

system such as KN assist.<br />

Provision of set-up and tool data via<br />

RFID technology<br />

As well as constant optimisation of machining times, the<br />

reduction of set-up and non-productive periods also always<br />

play an important role in a flexible production environment.<br />

In addition to machine concepts with optimised<br />

set-up times, KAPP NILES offers intelligent components.<br />

KN extender<br />

For set-up processes the technological data of components<br />

and tools is made available to the controller by using<br />

RFID technology, which enable an identification without<br />

any contact between antennas and RFID chips in the<br />

machine. In order to correctly identify the components,<br />

the operator is guided through intuitive step by step menu<br />

navigation, thus reducing the possibility for faulty inputs.<br />

22 no. 1, <strong>2020</strong>, March

materials & tools<br />

The key advantages of RFID technology are that it prevents<br />

incorrect component installation, it automatically<br />

reads and transfers component data, it prevents incorrect<br />

entries, which results in shortening of the overall input<br />

time, as well as preventing downtimes due to incorrect<br />

component installation.<br />

Tool data management and digital workbench<br />

KAPP NILES has developed its own platform called KN assist<br />

which contains a tool data management system among<br />

other features. Exchangeable, intelligent components with<br />

all geometric and process-related data can be managed and<br />

clearly displayed outside of the machine within the tool<br />

data management system. All tool data is therefore stored<br />

centrally in a single location and is retrieved from there.<br />

KN assist also provides supportive functions for the setup<br />

process. This means that essential assembly and disassembly<br />

operations for multi-part-<strong>tooling</strong> can be carried out<br />

by the operator in advance. This results in shorter preparation<br />

times for the subsequent grinding project. Furthermore,<br />

information is provided to the intelligent components<br />

which, together with the RFID technology, optimises<br />

the set-up process.<br />

CBN grinding worms<br />

KN assist, together with the KN extender (computer assembly<br />

for workshops, which equips workbenches with<br />

digital functionalities), manages the customer’s operation,<br />

labelling and management of all components outside of<br />

the machine. Besides the identification of components by<br />

RFID, optical component recognition is also possible. The<br />

system is designed to also manage components without<br />

RFID or a QR code/DMC identification.<br />

GrindTec <strong>2020</strong>, hall 3, booth 3001<br />

information: www.kapp-niles.com<br />

With additive manufacturing to more productivity<br />

If the weight of PCD tools is reduced, as a rule<br />

significantly higher cutting data can be used.<br />

Along with design freedom, the possibility of<br />

weight optimisation is one of the crucial advantages<br />

offered by 3D printing. Due to the specially<br />

developed structures inside the tool, which cannot<br />

be manufactured conventionally, the weight<br />

can be reduced significantly.<br />

New bell tool with low weight,<br />

long tool life and best cutting data<br />

An example of how MAPAL uses this advantage of 3D<br />

printing in practice is the new bell tools with brazed PCD<br />

inserts. Bell tools are used for the external machining of<br />

hose connections, among other applications. These connections,<br />

for example on turbochargers, must satisfy com -<br />

plex contour requirements. Manufacturing must be cor re -<br />

spondingly precise. Existing processes are also subject to<br />

continuous improvement so that manufacturing is costeffective<br />

and reliable in series production.<br />

MAPAL has therefore optimised the existing, conventionally<br />

manufactured bell tool. Using the selective laser<br />

melting process, the inside of the tool has been modified<br />

- instead of solid material there is now a specially designed<br />

honeycomb structure. As a consequence, the tool is<br />

30 % lighter and the tool life is increased by approx. 40 %<br />

due to the damping effect. It is therefore possible to machine<br />

faster; the machining quality remains at the same<br />

high level.<br />

MAPAL is presenting a new<br />

bell tool with low weight,<br />

long tool life and<br />

best cutting data<br />

The honeycomb structure<br />

inside the tool can be<br />

realised thanks to<br />

additive manufacturing<br />

In total the machining time has been reduced by 50 %.<br />

Furthermore, the cooling channel design has also been optimised.<br />

The new bell tool is of hybrid design. Using selective<br />

laser melting, the new tool geometry is printed on a<br />

highly precise tool body with a HSK-63 connection. The<br />

additively manufactured part is subsequently machined<br />

conventionally. Then the PCD inserts are brazed in place<br />

and cut to shape using a laser.<br />

information: www.mapal.com<br />

no. 1, <strong>2020</strong>, March<br />


materials & tools<br />

TIGRA with<br />

interesting innovations<br />

at the GrindTec show <strong>2020</strong><br />

For the Oberndorf-based company TIGRA the<br />

importance of the Augsburg GrindTec is growing<br />

each year. The world's leading tradeshow for<br />

grinding technologies takes place every two years<br />

and has proven itself for many years as an ideal<br />

platform to inform customers and interested parties<br />

of the latest developments and innovations for<br />

the processing of metal, composite materials, aluminium,<br />

board materials, wood and many more.<br />

Significant investments in TIGRA's production over the last<br />

few years have resulted in many innovations, which the<br />

Bavarian company will present at GrindTec <strong>2020</strong> in Hall<br />

5-5036. In the spotlight of the impressively grown product<br />

range for tool tipping are especially carbide blanks, which<br />

are manufactured in Oberndorf am Lech, as well as ultrahard<br />

cutting materials such as PCD and PcBN.<br />

Solid carbide blanks, so-called preforms, are used for<br />

the production of end mills with central and decentralised<br />

coolant holes, also with lateral exits at various angles<br />

and aligned with the chip surfaces. The chip spaces are<br />

preformed. The design of the blank dimensions is based<br />

on the customer's blank and finished drawings. The parts<br />

are subject to multi-stage quality controls and are near to<br />

finished contour, thus the customer has low grinding and<br />

erosion effort. Depending on the application, TIGRA offers<br />

two different carbide grades for this purpose, which have<br />

TIGRA has various carbide blanks in its program, the preformed<br />

blanks or so-called preforms are manufactured individually<br />

according to customer drawings; the milling cutter blanks are<br />

available from stock in the diameter range from 8 to 25 mm,<br />

they can have 2-5 radial coolant exits and are h6 ground,<br />

with or without Weldon surface<br />

TIGRA supplies PCD blanks and segments with PCD layer<br />

thicknesses of 0.5, 0.7 and 1 mm, the segments are laser-cut or<br />

eroded according to customer requirements, for the hard milling<br />

sector, blanks and segments are available made of PcBN<br />

optimized soldering and toughness properties for tipping<br />

with PCD or PcBN. TIGRA's short delivery times are also<br />

important for the customer.<br />

Further carbide blanks are flat bars and rods in application-specific<br />

carbide grades and in various dimensions,<br />

standard milling cutter blanks with central coolant hole<br />

and two to five radial coolant exits as well as carbide inserts<br />

for positive and negative plates for tipping with diamond<br />

and PcBN. The wide range of saw tips for circular<br />

and band saws will also be presented to the international<br />

trade visitors. They are manufactured in metric and inch<br />

sizes. Unique to TIGRA is the fact that every single saw tip<br />

is subject to 100 % quality control! Depending on the carbide<br />

grade, the carbide saw tips are used for sawing steel<br />

with coolant, for cutting non-ferrous metals, for machining<br />

cast iron and for heavily interrupted cuts.<br />

Further information at www.tigra.com or from the new<br />

TIGRA catalogue for the machining of metal and composite<br />

materials, which will be published at GrindTec. During<br />

the tradeshow, TIGRA offers interested visitors the opportunity<br />

to visit the nearby company by shuttle vehicle and<br />

to see the production processes with a tour of the company.<br />

Further information is available on site at the exhibition<br />

stand or via TIGRA's service sales@tigra.com.<br />

GrindTec <strong>2020</strong>, hall 5, booth 5036<br />

information: www.tigra.com<br />

24 no. 1, <strong>2020</strong>, March



Fritz Studer AG, established in 1912, is a market and technology<br />

leader in universal, external and internal cylindrical grinding as<br />

well as noncircular grinding. Visit us at MACH <strong>2020</strong> on our<br />

booth 530, hall 7.<br />

studer.com<br />

The Art of Grinding.<br />

A member of the UNITED GRINDING Group

materials & tools<br />

LACH DIAMANT looks back on 98 years - third part - Hard turning<br />

Poly - poly - or what?<br />

How grinding times of several hours became turning times<br />

of a few minutes…<br />

Horst Lach, managing director<br />

and CEO of LACH DIAMANT<br />

agreed to write an ongoing series<br />

of articles about the development<br />

of diamond and CBN tools<br />

and grinding wheels in modern<br />

industries.<br />

Horst Lach is known as a true industry<br />

veteran, and we are excited<br />

to have this pioneer of techno -<br />

logy share some insights from<br />

over 59 years of professional experience<br />

in the diamond tool<br />

business.<br />

In the fifth part of this (almost)<br />

historical review, Horst Lach<br />

looks back to the very beginnings<br />

of hard turning.<br />

We are in part three of our article<br />

series “Poly - poly - or what?”,<br />

looking back at the time between<br />

autumn 1974 and the Hanover<br />

Trade Show in the spring of 1975.<br />

Dealing with this new cutting material<br />

“polycrystalline diamonds” (PCD) was<br />

fascinating for all of us; after the presentation<br />

at the first Hanover Trade<br />

Show in 1973, each day brought new<br />

insights for production and for different<br />

applications. The diamond cutters<br />

- familiar with the production of<br />

natural turning diamonds and polished<br />

turning diamonds for the jewellery<br />

industry and for the turning of<br />

copper commutators - were especially<br />

amazed by the superior cutting abilities<br />

of this new material in comparison<br />

with natural diamonds.<br />

Two examples: Interrupted cuts, almost<br />

in all cases disastrous for natural<br />

diamonds. PCD allows for high feed<br />

rates up to the cutting width (even<br />

for the now available “large” PCD cutting<br />

edges), while natural cutting edges<br />

only allow for a range within µ- or<br />

up to 1/100 mm for selected materials.<br />

Despite this fact, or now more than<br />

ever, development, production and<br />

application of the first PCD tools was<br />

successful in the end; it was a team<br />

effort and based on the professional<br />

know-how of diamond cutters such as<br />

Konrad Wagner, a master of natural<br />

diamond grinding who unfortunately<br />

died much too early, and Gerhard<br />

Mai with the assistance of machining<br />

expert Kurt Hemerka (grinding<br />

wheel production).<br />

Polycrystalline diamond materials<br />

resisted even the most artistic skills<br />

of natural diamond cutters on traditional<br />

cast grinding wheels (“poly”<br />

means “much” and does not have any<br />

growth to guide the trained eye of a<br />

diamond cutter). A grinding test on<br />

a resin-bond grinding wheel, manufactured<br />

by LACH DIAMANT, proved<br />

to be so successful that we started<br />

to look for a stable and precise tool<br />

grinding machine. We found a machine<br />

manu factured by Kelch, which<br />

we co-devel oped especially for PCD<br />

grinding. After a license transfer, we<br />

continued to build the “pcd-100/300”<br />

precision tool grinding machine for<br />

single-tipped PCD and carbide tools<br />

(see also “Poly - poly - or what?” part 1<br />

and 2).<br />

All this obvious excitement, only<br />

one and a half years after the first PCD<br />

introduction in 1973, brings to mind<br />

another great innovation. “Start with<br />

Borazon ® ”, the abrasive of a new era,<br />

had been presented at Hanover Trade<br />

Show in 1969. Borazon ® CBN grinding<br />

wheels from LACH DIAMANT<br />

are so well known among tool grinders<br />

in the tool manufacturing industry<br />

- as tool and inside grinding<br />

wheels with increasing production, as<br />

peripheral grinding wheel for surface<br />

and circular grinding - that the name<br />

“Borazon ® ” is clearly associated with<br />


First presentation in Hanover in 1975 - hard turning instead of grinding<br />

“Borazon ® ” was there something<br />

else? As I remember (see “Poly - poly<br />

- or what?” first part) I had expected<br />

a polycrystalline CBN cutting material<br />

back in the beginning of 1973 -<br />

a sort of “compact Borazon ® cutting<br />

edge”.<br />

26 no. 1, <strong>2020</strong>, March

materials & tools<br />

Moscow beckons with a new<br />

cutting material “Elbor”<br />

As luck would have it, we received an inquiry from Hempel<br />

company, Düsseldorf, which had good business contacts to<br />

Moscow, and they asked whether we would be interested<br />

in a new cutting material named “Elbor” manufactured in<br />

the USSR, a compact CBN material, compressed through<br />

high-pressure synthesis.<br />

Of course, yes! Electrified - that would be an understatement.<br />

And so it happened that Konrad Wagner and I flew<br />

to Moscow from East Berlin in 1974, in a Tupolew - first<br />

class as VIPs, organized by Hempel.<br />

The impressions and experiences of this short trip right<br />

before Christmas, to an, at that time, unknown world for<br />

us would be worth a separate report. We found out that<br />

we got to Moscow<br />

at the invitation of<br />

the Russian Ministry<br />

of Food & Agriculture.<br />

This government department<br />

supervises<br />

15 high-technology<br />

institutes/manufacturers<br />

for synthetic<br />

diamonds and CBN.<br />

Polycrystalline Elbor’-CBN blade,<br />

sintered into a matrix<br />

At that time,<br />

we visited the<br />

“Tomilins ky Factory”<br />

near Moscow, founded<br />

in 1959, and according<br />

to their own<br />

accounts one of the<br />

leading manufacturers<br />

of diamond tools<br />

in the former Soviet Union, and from the 60’s onwards<br />

also a manufacturer of diamond and CBN grains. Here we<br />

should get to know “Elbor”. A “new” cutting material, until<br />

then unknown in the Western world, designed to make<br />

machining tools for hard machining.<br />

dreborid-G-AS during machining of a<br />

metal powder coated steel part<br />

our flight back, we had to cancel a visit to the top secret<br />

“Institute for Super Hard Materials V Bakal” in Kiev/<br />

Ukraine. We had an invitation from the ministry, and they<br />

would have even taken us by helicopter to this research<br />

facility, with up to 1.000 employees.<br />

Unexpected help by coincidence<br />

Back in Hanau, we started our first preparations for the<br />

Hanover Trade Show in 1975. What should we do with<br />

“Elbor”? We received unexpected help by coincidence,<br />

sure enough via Borazon ® : a “customer problem” in regards<br />

to surface grinding a metal powder coated cylinder.<br />

The customer thought that grinding times with the CBN<br />

grinding wheel were too long. “Well, let’s try this compact<br />

CBN «Elbor».“<br />

Thought and done. However, as expected, soldering<br />

without a carbide holder, as with PCD, was unsuccessful.<br />

At that time, we did not have the option to solder within a<br />

vacuum, and so we had to sinter the “Elbor” cutting edge.<br />

The first attempt of making a turning tool in this way was<br />

already successful.<br />

By that time, we were very familiar with Borazon ® CBN<br />

grinding wheels, made from high-alloy hardened steel<br />

from 58/62 HRc. Compared to grinding, it should be easy<br />

to use this CBN composite mixture (unlike diamonds<br />

stable up to 1.500° C) for the superior turning of these<br />

steels. In this context, the reference to PCD, the polycrystalline<br />

diamond of General Electrics.<br />

However, the CBN composite material named “Elbor”<br />

consisted of a unit with an 8 mm radius and a thickness of<br />

approximately 6 mm. There was no carrier or carbide layer,<br />

which would have provided for a solid soldered joint. We<br />

found comfort in the thought that we would - as usual<br />

- find a solution in order to achieve a stable connection<br />

between “Elbor” and holder.<br />

A license contract for the raw material “Elbor” was<br />

signed. Unfortunately, on December 22nd, shortly before<br />

Enthusiastic responses and amazement during the<br />

first presentation of dreborid-G-AS<br />

no. 1, <strong>2020</strong>, March<br />


materials & tools<br />

“This will be our trade show highlight - we will demonstrate<br />

it on a Weiler turning lathe”. And so it happened:<br />

at Hanover Trade Show in spring the “new” product was<br />

successfully presented as “dreborid-G-AS” for machining<br />

of metal powder coated turning parts. For the first time,<br />

hours of grinding times were reduced to minutes of turning<br />

times, and the surfaces were just as polished.<br />

The first step towards better performance and more efficiency<br />

was done. At first it was only a niche market; mainly<br />

Metco (today Oerlikon-Metco) and Castolin, among other<br />

manufacturers for metal powder coatings, considered the<br />

dreborid-G-AS turning tools almost as a gift. Too many<br />

customers complained about long grinding times during<br />

the equalisation of flame-sprayed turning parts with nickel,<br />

chrome and wolfram carbide alloys, no matter whether<br />

for repairs or wear protection. Right away, we achieved up<br />

to 90 % reductions - turning instead of grinding (as mentioned<br />

in MM Maschinenmarkt, issue #3/1976, April).<br />

The search for other possible applications<br />

During the initial phase, Metco and Castolin provided<br />

all their technicians with LACH DIAMANT developed<br />

repair kits, containing one dreborid-G-AS turning steel<br />

and a special development, a dreborid-G-diamond grinding<br />

wheel. Due to the low hardness of CBN, compared to<br />

PCD, even inexperienced tool grinders were now able to<br />

re-grind the cutting edge.<br />

Encouraged by these first experiences and during our<br />

search for other possible applications, we were inspired by<br />

the positive experiences during the use of Borazon ® CBN<br />

grinding wheels. In fact, both procedures, grinding and<br />

turning, could handle materials like high-alloyed hardened<br />

steel with a hardness of 58 and 62 HRc.<br />

We realized that from now on, there would be a “gap”<br />

between grinding with CBN and machining with polycrystalline<br />

CBN cutting materials results, despite of continued<br />

attempts of machining tool manufacturers to counteract<br />

this tendency with newly developed types of carbides<br />

and ceramics.<br />

The alternative to Elbor<br />

The readers will likely assume that the first successful attempts<br />

during hard machining were owed to the imported<br />

CBN cutting material named “Elbor”, but with the initially<br />

worried-about disadvantage. A solid carbide basis for soldering<br />

was missing from the 8 mm Ø CBN compact unit.<br />

More and more often, we ran into the problem that the<br />

“precious” Elbor cutting edge would break out of its matrix<br />

after 30 to 35 % usage.<br />

There was no other alternative manufacturer of polycrystalline<br />

CBN cutting edges. Until the end of 1975, when<br />

our PCD supplier GE surprisingly informed us that we<br />

could order polycrystalline “BZN-compact” boron nitride<br />

cutting edges from GE, with a carbide basis for soldering.<br />

Without any hesitation, we switched to “BZN-compact”.<br />

Apparently, this polycrystalline material had already<br />

been developed in the mid 60’s, in order to offer it to GE<br />

subsidiary Carbology. They were not interested at that time<br />

and did not want to have anything to do with products<br />

“superior to carbide”. That is how Louis Kapernaros (at the<br />

time General Manager at GE – Super Abrasives, Worthington,<br />

Ohio/USA) described the situation years later when<br />

we had the punch line in this regard: when we presented<br />

CBN tools at the Hanover Trade Show in 1975, Carbology<br />

in Frankfurt had already BZN inserts in their safe for some<br />

time…<br />

All told, once again the first step to the introduction of<br />

a new technology had been taken - let’s simply call it the<br />

“hour of birth of hard turning”…<br />

dreborid-G-AS during turning of a<br />

metal powder coated steel part<br />

Horst Lach<br />

further information: www.lach-diamant.de<br />

28 no. 1, <strong>2020</strong>, March

fairs<br />

news & facts<br />

8 th world’s leading trade fair for<br />

industrial coating technologies<br />

Surface finishing is the decisive criterion for the suc -<br />

cess of products, and thus for a company’s competitive<br />

edge.<br />

Consequently, industrial coating technologies make an essential<br />

contribution to value creation. Companies with inhouse<br />

painting operations and coating job-shops are faced<br />

with changing and new requirements as a result, which<br />

necessitate corresponding process adjustments. PaintExpo<br />

will present the world’s most comprehensive and futureoriented<br />

solutions to this end at the Karlsruhe Exhibition<br />

Centre from April, the 21 th through the 24 th , <strong>2020</strong>. The exhibition<br />

portfolio covers everything from pre-treatment, right<br />

on to quality control and packaging.<br />

A wide variety of trends and changes will be shown,<br />

such as new manufacturing technologies, new and modified<br />

materials and material combinations, the realignment<br />

of entire industry sectors, shortened product lifecycles and<br />

smaller lot quantities, personalisation of products, regulatory<br />

changes, the digital transformation and other goals<br />

concerning energy efficiency and climate protection. Industrial<br />

coating technology is concerned by this as well.<br />

High levels of complexity necessitate<br />

comprehensive information<br />

Although some of the issues are by no means new, the com -<br />

petitiveness of coating operations will increasingly depend<br />

on how well and quickly they can respond to these changes.<br />

As a prerequisite, the coating process has to be adapted or<br />

optimised. The great complexity of painting and coating<br />

pro cesses with numerous interlinking work steps makes<br />

comprehensive information concerning trends, technologies,<br />

new developments and the suppliers throughout the<br />

entire process sequence indispensable. PaintExpo will present<br />

a corresponding cross-technology, cross-industry over -<br />

view with more comprehensive and up-to-date offerings<br />

than anywhere else in the world.<br />

Exhibitors will present future-oriented solutions for meeting<br />

the increasing demands on quality, flexibility and productivity,<br />

as well as material, energy and cost-efficiency.<br />

For example, these include new and further developments<br />

for classic wet chemical pre-treatment, as well as alternative<br />

processes.<br />

further information: www.paintexpo.com<br />

Quattrotec –<br />

Intelligent turningdrilling<br />

applications<br />

with EasySafe system<br />

12. - 15. May <strong>2020</strong><br />

Hall A, Booth A0827<br />

■ Drilling into solid material with flat drilling<br />

base (including off-centre drilling), inside<br />

turning, face cutting and longitudinal turning<br />

– performed with low vibrations and just a<br />

single tool<br />

■ EasySafe System – A notch on the under<br />

side of the indexable insert ensures that it<br />

can be fitted into the seat speedily and<br />

100% correctly<br />

■ Reduces machining and tool changing times<br />

■ Optimal cutting grades will be available for<br />

almost every application<br />


news & facts<br />

fairs<br />

GrindTec <strong>2020</strong>: World’s leading trade fair for<br />

Grinding technology continues to grow despite<br />

difficult framework conditions<br />

The ongoing trade crisis with the USA, the automobile<br />

market shrinking worldwide for the first<br />

time and the difficult transformation process to<br />

E-mobility taking place in this country.<br />

And yet: The AFAG GrindTec organizers currently have<br />

663 registrations, a moderate increase in comparison to<br />

the 629 participating companies in January 2018. The<br />

occupied area has been enlarged. On an area of 46,500 m 2<br />

GrindTec will present more exhibits than ever before. The<br />

number of nations participating has also increased, companies<br />

from 31 countries (29 in 2018) - present status - will<br />

present their innovations in Augsburg. The proportion of<br />

foreign exhibitors totals 44 %.<br />

Grinding techology positions itself with<br />

exciting trends<br />

An encouraging sign is thus set by the international grinding<br />

technology, which continues to show great interest in<br />

the German market and further pins its hope at GrindTec.<br />

Even though “harsher winds are blowing”, because grinding<br />

technology is closely interwoven with the automobile<br />

and engineering branch. Trade conflicts as well as sanctions<br />

from major nations are currently having a negative<br />

effect on the global economy and as a result also on the<br />

branch. Added to this are political uncertainties and structural<br />

changes in the automobile industry.<br />

Thus in the third quarter of 2019, incoming orders decreased<br />

in Germany by about a quarter. Foreign trade,<br />

which is extremely important for an export country like<br />

Germany, is less affected. Seen globally, experts reckon<br />

here with a decrease of only 4 % for the year <strong>2020</strong>.<br />

Despite all uncertainties the market is still strong!<br />

Measured against the product value of machine tools in<br />

Germany, the machine group of “grinding, honing, lapping<br />

and polishing machines” makes up more than 13 %<br />

of all cutting and filing machine tools. In addition to this<br />

is the turnover through the production of grinding tools<br />

and abrasives, which in Germany with more than a billion<br />

Euro is just as high as that of the german “grinding,<br />

honing, lapping and polishing machines”. A good reason<br />

for the branch to counter the current economic situation<br />

with innovations, trend-setting methods and advanced<br />

technologies, and to present itself at GrindTec at the usual<br />

high technical and technological level.<br />

High-tech products on everything to do with the production<br />

and reprocessing of cutting tools are opening up<br />

new perspectives for tool grinding. Here the branch has its<br />

sights set firmly on competitive methods such as additive<br />

manufacturing, electrochemical polishing methods and<br />

laser processing of hard materials, whilst at the same time<br />

offering the<br />

market<br />

highly<br />

functional<br />

solutions<br />

for tried<br />

and tested<br />

processes.<br />

What - amongst other things - GrindTec visitors<br />

can expect:<br />

➤ additive manufactured grinding discs<br />

➤ grinding discs with integrated sensor technolog<br />

➤ additive manufactured flow-optimised cooling<br />

lubricant nozzles<br />

➤ hybrid grinding machine concepts that also integrate<br />

other manufacturing technologies<br />

➤ direct drives in the grinding machine shafts to improve<br />

dynamic stiffness and precision as well as improving<br />

performance, to name just a few examples.<br />

Digitalisation, networking and automation form the basis<br />

for companies wanting to be successful on the world market.<br />

The manufacturers of machines and periphery systems<br />

as well as process and tool technology also supply<br />

sanswers at GrindTec to the new demands made of tool<br />

grinding. Providing added value in production technology<br />

at different places in the world at the same time is<br />

only possible with a modern network economy. New business<br />

models with economic potential will arise. Technologies<br />

such as augmented reality and virtual reality will help<br />

both the supplier and the user/customer to simplify the<br />

daily work routine. Here numerous inspirations will likewise<br />

be found at GrindTec.<br />

FDPW - competence centre for<br />

grinding technology<br />

The Trade Association of Precision Toolmakers (FDPW), together<br />

with its international partners, presents itself in the<br />

conference centre of the Augsburg exhibiton centre. In addition<br />

to this, the association’s service partners also introduce<br />

themselves personally and supply information about<br />

their offers, which could be of great interest to the grinding<br />

technology companies. The GrindTec Forum with its<br />

lectures on current themes and the Jakob Preh school from<br />

Bad Neustadt, which is the only vocational school that<br />

trains precision toolmakers, can also be found here. Together<br />

with the GrindTec Campus this combination supplies<br />

insight into the cutting edge of user related research<br />

and development - the ideal complement to the comprehensive<br />

offers of further GrindTec exhibitors.<br />

further information: www.grindtec.de<br />

30 no. 1, <strong>2020</strong>, March

companies<br />

news & facts<br />

Launching the SEAM Program<br />

After years of unwavering commitment to quality<br />

and safety in the use of abrasives and production<br />

processes, European abrasive companies are again<br />

joining forces to implement sustainability measures<br />

industry-wide, thanks to SEAM.<br />

environment<br />

labor<br />

economy<br />

FEPA, the Federation of European Producers of Abrasives, representing<br />

over 80 % of the European producers of abrasive<br />

products, announced the launch of its new program<br />

focused on sustainability: SEAM - Sustainable European<br />

Abrasive Manufacturers.<br />

With the understanding that the value of a “European<br />

sustainability system” must involve all players within the<br />

supply chain, the objective of the program is to support<br />

and assist abrasive manufacturers on their way towards sustainable<br />

growth and sustainability improvements, mostly<br />

in production and distribution.<br />

The plants of the SEAM members enrolled in the program<br />

must meet a series of minimum requirements orga-<br />

nized into the three fundamental pillars of sustainability:<br />

environment, labor and economy. Each company must<br />

adopt several evolving targets within the three pillars,<br />

such as energy management, employee safety and business<br />

continuity. SEAM members must report annually on their<br />

progress.<br />

“Sustainability is not just a trend. It is bigger than that.<br />

Today it is a call for action to companies to act socially responsible.<br />

And SEAM is the answer to this call. It demonstrates<br />

the willingness of the European abrasive producers<br />

to work on making their production more sustainable,<br />

more efficient, and take a stronger look at the people who<br />

work for them and the community they belong to,” stated<br />

Jan Cord Becker, CEO of<br />

Hermes Abrasives and president<br />

of FEPA.<br />

Large, medium and small<br />

size abrasive manufacturers,<br />

suppliers and distributors<br />

have joined SEAM to set a<br />

European sustainability<br />

standard that pulls industry<br />

upward where it can find<br />

the right balance between<br />

environmental efficiency,<br />

production performance,<br />

labor safety; all pieces of a<br />

puzzle that betters the life<br />

of a community, and are<br />

values which give a strong<br />

position to European companies<br />

in the world.<br />

further information:<br />

www.fepa-abrasives.org<br />

no. 1, <strong>2020</strong>, March<br />


news & facts<br />

companies<br />

CECIMO elects Hans-Martin<br />

Schneeberger as the new president<br />

During its meeting held December 5, 2019 in Brussels,<br />

the CECIMO General Assembly elected Dr. Hans-Martin<br />

Schneeberger as president of CECIMO for a period of two<br />

years. His term will focus on the setting of global standards<br />

and the uptake of artificial intelligence.<br />

Succeeding in this role Dr. Roland Feichtl, Dr. Hans- Martin<br />

Schneeberger has been entrusted with the responsibility<br />

of leading the European Association that represents more<br />

than a third of the world machine tool (MT) production.<br />

Dr. Schneeberger is a Swiss citizen born May 14, 1955.<br />

He has been serving as chairman of the board of directors<br />

of Schneeberger Holding AG since 2003. Between 1993<br />

and 2018 he was CEO of the company and between 1988<br />

and 1993 managing director and head of marketing and<br />

sales of Schneeberger AG. From 1985 - 1988 Dr. Schneeberger<br />

was account and project manager within a European-based<br />

management consulting firm. Since 2007 he<br />

has been mem ber on the board of Klingelnberg AG, while<br />

from 2008 - 2018 served as<br />

board member of Unitectra<br />

AG, being chairman of the<br />

board 2014 - 2018. Previously<br />

he chaired the board of<br />

Inspire AG. He was a member<br />

of the board of Swissmem and<br />

for many years a delegate to<br />

CECIMO, the European Machine<br />

Tool Builders Association<br />

Hans-Martin Schneeberger<br />

in Brussels.<br />

Dr. Schneeberger obtained a PhD from the Krannert<br />

business school (Purdue University, USA) in 1984 and was<br />

tenure track assistant professor at the Ross business school<br />

(University of Michigan, 1984 - 1985). Before he received a<br />

BSc in mechanical engineering in Switzerland.<br />

further information: www.cecimo.eu<br />

New partnership with<br />

Ellison Technologies in the U.S.<br />

Heller Machine Tools are changing their business<br />

model in the North American market.<br />

For the first time ever, Heller has moved to both direct and<br />

distribution sales and service - providing their customers<br />

with a more local interface that can provide sales, engineering<br />

and customer support via their new distribution<br />

network and still maintain the existing direct key account<br />

business.<br />

Heller Machine Tools L.P. are pleased to announce a new<br />

distribution partnership with Ellison’s Advanced Technologies<br />

Business Unit in the U.S.; with specific repre sentation in<br />

the following states: Alabama, Delaware, Georgia, Illinois,<br />

Maryland, Mississippi, Nebraska, North Carolina, South<br />

Carolina, Tennessee and Virginia.<br />

The Ellison Company was founded by James O. Ellison<br />

in 1955, the company was based in Southern California to<br />

distribute machines tools and provide after sales service.<br />

After continued expansion and organic growth, Ellison<br />

reached 2012 a half billion USD in sales and became one<br />

of the most successful machine tool suppliers in the USA.<br />

2015 the company celebrated its 60 th anniversary.<br />

Today Ellison Technologies is part of Mitsui & Co., Ltd.<br />

of Japan, which has allowed the company to increase its<br />

business foot print, as a provider of advanced machining<br />

solutions to the North American metal cutting manufacturers<br />

and their global affiliates.<br />

further information: www.heller.biz<br />

1 st International Conference on Programmable Materials<br />

Imagine the rotor of a wind turbine with a surface<br />

that, depending on the amount of wind, forms<br />

small dents or scales upon itself in order to control<br />

the energy yield and the mechanical stress<br />

for the entire system.<br />

The material acts proactively and responds to the external<br />

conditions in the manner in which it was programmed.<br />

This is the vision of programmable materials. In order to<br />

exploit the potential of programmable materials, both the<br />

internal structure of the material and its inherent material<br />

properties must be thought of as changeable variables. In<br />

order to achieve the desired outcome at the correct point<br />

in time when the product is in use, information processing<br />

has to take place directly within the material. This is a para -<br />

digm shift in product development that demands more than<br />

material competence. Engineering sciences, natural sciences<br />

and computer science must all work together in a new way.<br />

This is where the 1 st International Conference on Programmable<br />

Materials comes in. From April 27 - 29, <strong>2020</strong>, experts<br />

from a wide range of disciplines will meet in Berlin<br />

to learn from each other and to advance the development,<br />

production and use of programmable materials.<br />

further information: www.iwm.fraunhofer.de<br />

32 no. 1, <strong>2020</strong>, March

companies<br />

news & facts<br />

New president of CemeCon Inc.<br />

Majorie Steed takes the lead<br />

from Gary Lake<br />

Change of leadership in the North American CemeCon<br />

branch: On August 1 st , Marjorie Steed succeeded Gary<br />

Lake, leading the business of CemeCon Inc. Her promotion<br />

is part of a planned transition.<br />

For 21 years CemeCon Inc. has been supplying North<br />

American tool manufacturers with premium coatings and<br />

coating technology. Over the years, the company has repeatedly<br />

expanded its capacity to meet increasing demand.<br />

In 2004, the subsidiary of CemeCon AG moved to its current<br />

headquarters, the IST Center in Big Flats, New York.<br />

For a long time CemeCon Inc. focused on PVD coatings;<br />

since September 2014, the company has also been using the<br />

world-leading diamond technology from CemeCon to coat<br />

cutting tools. With the latest expansion of the new North<br />

American headquarters to 3,700 m 2 in 2018, CemeCon<br />

Inc. increased the capacity of their diamond production<br />

and made room for the future-oriented<br />

HiPIMS coating<br />

technology.<br />

After 20 years of growth,<br />

CemeCon Inc. employs more<br />

than fifty people today.<br />

Marjorie Steed began her career<br />

at CemeCon 2006. In<br />

2015, she was named to the<br />

Marjorie Steed, new President<br />

of CemeCon Inc.<br />

CemeCon Inc. board of directors and became vice president<br />

of operations. On August 1 st , she replaced Gary Lake<br />

as President of CemeCon Inc., who led the fortunes of the<br />

North American subsidiary of CemeCon AG for over twenty<br />

years.<br />

further information: www.cemecon.de<br />

Responding to downturn in metalworking industry<br />

Europe-wide reorganization measures<br />

LMT Tools continues to implement its strategic<br />

measures to improve competitiveness. Three transformation<br />

projects are driving the change.<br />

With this step, the company is also reacting to changed<br />

market conditions in the metalworking industry. In times of<br />

generally declining demand in the metalworking industry,<br />

LMT Tools is consistently pursuing its strategy, initiated<br />

in 2017, to improve competitiveness. The company is<br />

launching three restructuring programs in the areas of<br />

sales, pro duct management and production, which will be<br />

implemen ted by the end of the year. The focus is on increasing<br />

operational efficiency, which also addresses ex-<br />

cess capacities in Europe. The existing product portfolio<br />

remains unaffected by the measures.<br />

LMT Tools will create an agile, customer-centered organization<br />

within the sales region EMEA. The company<br />

strengthens its technical sales organization with local appli<br />

cation expert teams and creates efficient, highly customer-centered<br />

structures.<br />

Additionally LMT Tools advances the development of its<br />

product portfolio at the high-technology sites in Europe by<br />

focussing on growth areas. A global product management<br />

will be implemented.<br />

further information: www.lmt-tools.com<br />

Chris Yates elected new<br />

EMVA President<br />

The European Machine Vision Association (EMVA)<br />

announced that Chris Yates is president of the<br />

EMVA effective from the 1 st January <strong>2020</strong>.<br />

Chris succeeds Jochem Herrmann, who has been president<br />

since 2015 and now decided to step down for spending<br />

more time with his family. According to the association<br />

statutes, Chris's election was agreed by the board of directors<br />

of the EMVA during a board meeting in Berlin, where<br />

he was elected unanimously.<br />

Dr Chris Yates is the director of Advanced Technology<br />

within the Safety, Sensing, & Connectivity business of<br />

Rockwell Automation, having<br />

previously been the CEO and<br />

founder of Odos Imaging prior<br />

to the company's acquisition<br />

by Rockwell Automation<br />

during 2017. Chris holds a degree<br />

and Ph.D from Imperial<br />

College London, and has held<br />

a number of senior roles in<br />

early stage companies, con centrating<br />

on the effective translation<br />

of novel technology to<br />

products in the market.<br />

further information: www.emva.org<br />

Chris Yates<br />

no. 1, <strong>2020</strong>, March<br />


news & facts<br />

companies<br />

Partnership creates large independent global<br />

producer of cemented carbide tool blanks<br />

Hyperion Materials & Technologies, a global leader<br />

in developing hard and super-hard materials for a<br />

wide range of demanding applications, completed<br />

January 1 st the acquisition of AFC Hartmetall, a<br />

premium cemented carbide tool blank manufacturer,<br />

marking the close of the highly complementary<br />

agreement announced in September.<br />

“Bringing AFC into the Hyperion group creates an extensive<br />

product portfolio and expands our manufacturing<br />

capabilities, boosting our already robust offering and further<br />

positioning us as the first choice for toolmakers in<br />

need of high-precision, high-performance solutions for<br />

drilling and milling applications,” said Ron Voigt, CEO of<br />

Hyperion. “AFC has an extremely talented workforce and a<br />

tremendous reputation for supporting customers. Together,<br />

we will work toward the shared goal of becoming the<br />

world’s top independent supplier of cemented carbide tool<br />

blanks.”<br />

There will be little change as the companies begin the<br />

integration process. AFC will maintain its own brand identity<br />

and continue operations at its Mainleus, Germany,<br />

headquarters. AFC founder Arno Friedrichs stepped down as<br />

CEO and joined the Hyperion board of directors, and Ralf<br />

Greifzu, who has led AFC’s global sales for seven years, is<br />

now vice president and general manager of AFC. In addition,<br />

AFC employees will participate in Hyperion’s shared<br />

employee equity program.<br />

further information: www.hyperionmt.com<br />

Swiss CNC technology leader expands to India<br />

NUM AG has opened a branch in Bangalore. With<br />

this expansion in Asia, the international com -<br />

pany with headquarters in Teufen, Switzerland,<br />

further reinforces its position as a technology<br />

leader in the field of CNC controls. With the expansion<br />

to India, NUM increases its local presence<br />

there as well as its customer-oriented sales and<br />

service offering.<br />

“The location in Bangalore will enable us to respond much<br />

more quickly to customer enquiries and further expand<br />

our brand in the region. We have been well represented in<br />

China and Taiwan for many years and would now like to<br />

further strengthen our position in Asia,” says Rajesh Nath,<br />

managing director of NUM India. This latest expansion secures<br />

jobs worldwide, as well as creating new employment<br />

opportunities in India.<br />

Rajesh Nath and NUM CEO Peter von Rüti set up the<br />

branch in the south of Bangalore. “By opening a branch in<br />

India, we are exploiting our growth potential. At the same<br />

time the Indian team is expanding our expertise in sales,<br />

service and after-sales support,” adds von Rüti. NUM believes<br />

that Bangalore, as a high-tech location, will strongly<br />

influence the CNC market in the future and thus significantly<br />

promote the development potential for CNC controls.<br />

With the new office in Bangalore, NUM is now represented<br />

internationally at twelve locations.<br />

further information: www.num.com<br />

34 no. 1, <strong>2020</strong>, March

companies<br />

news & facts<br />

STUDER increases its market share again in 2019<br />

After a record year in 2018, Fritz Studer<br />

AG reported another very successful<br />

year in 2019. With the third best annual<br />

turnover in the company's history,<br />

the cylindrical grinding machine<br />

manufacturer increased its market<br />

share again, despite difficult market<br />

conditions. One reason for its success<br />

is the high proportion of new customers,<br />

at almost 40 %.<br />

Sales & machine portfolio<br />

At the annual press conference Jens Bleher,<br />

CEO of Fritz Studer AG, reported<br />

a successful 2019, even if the economic<br />

situation has deteriorated significantly.<br />

“With the third best year in the company's<br />

history we were able to further increase<br />

our market shares”, says Sandro<br />

Bottazzo, the company's CSO. STUDER recorded<br />

strong growth in North America in particular, where it<br />

achieved the second best result in the company's 100-year<br />

history. The company was also able to further increase<br />

its turnover with internal cylindrical grinding machines.<br />

“In the Asian region in particular we maintained incoming<br />

orders for internal cylindrical grinding machines at<br />

the high level<br />

of 2018”, continues<br />

Bottazzo.<br />

Three machine<br />

types<br />

also achieved<br />

record incoming<br />

orders: the<br />

S121, the S141<br />

and the S151,<br />

the flagship of<br />

internal cylindrical<br />

grinding<br />

machines.<br />

The new univer<br />

sal cy lindri<br />

cal grinding<br />

machines -<br />

the favorit,<br />

the S33 and<br />

the S31 - have<br />

also got off to<br />

a very successful<br />

start. “The<br />

launch of the<br />

Stephan Stoll (COO), Sandro Bottazzo (CSO),<br />

Daniel Huber (CTO) und Jens Bleher (CEO)<br />

new universal machines was both a feat of strength and a<br />

highlight”, explains Bleher. The company didn't even need<br />

a year to sell around 100 of the new machines. Customers<br />

underscore the top quality and precision of the new<br />

machines. In America a long standing STUDER customer,<br />

who had purchased a new S31, was delighted that he could<br />

achieve another increase in reliability and precision.<br />

Our goal is to make our customers<br />

even more successful<br />

The customer segments developed very differently in<br />

2019. In the automotive sector in particular, market conditions<br />

were much more challenging than in 2018. However,<br />

thanks to this broad diversification Fritz Studer AG<br />

was able to offset weaker market segments with stronger<br />

ones. For example, the aviation industry was one of the<br />

segments that flourished in 2019. “Our company has also<br />

been very well positioned in the aerospace customer segment<br />

for many years and is a preferred supplier of many<br />

component suppliers”, explains Bottazzo, when reviewing<br />

the past year. STUDER sees one key to its success in<br />

its global customer-focused sales and service organization.<br />

This is also one of the reasons why the proportion of new<br />

customers was almost 40 % last year. Smaller markets, like<br />

Great Britain, also achieved a very good order intake in<br />

2019. Finally, the market share was also increased in the<br />

company's home market of Switzerland.<br />

GrindTec <strong>2020</strong>, hall 2, booth 2055<br />

further information: www.studer.com<br />

no. 1, <strong>2020</strong>, March<br />


processes<br />

Additive manufacturing:<br />

Opportunities for cutting tool manufacturers<br />

written by: Thomas Götz, Andreas Gebhardt and Dr. Marco Schneider,<br />

authors from the Fraunhofer Institute for Manufacturing Engineering and Automation IPA<br />

Currently, small and medium sized enterprises<br />

(SMEs) within the German cutting tool industry<br />

encounter a wide range of challenges. Customer<br />

requirements in terms of productivity, quality<br />

consistency and tool life are constantly rising.<br />

In addition, the sector is undergoing a profound<br />

change driven by digitization and a fundamental<br />

transformation of the automotive industry due to<br />

powertrain hybridization and electrification. From<br />

a market perspective, the industry is increasingly<br />

exposed to competition with low-cost cutting<br />

tools mainly from Asian countries.<br />

Hence, for German cutting tool manufacturers and particularly<br />

SMEs reduction of manufacturing costs as well<br />

as access to new technologies and manufacturing processes<br />

are keys for maintaining their technological leadership<br />

position on the world market in the medium to long<br />

term. The issue of suitable technologies and innovative solutions<br />

for the future production of cutting tools was addressed<br />

within the framework of the “Innovationsforum<br />

Zerspanwerkzeuge” at last year’s International Exhibition<br />

for Metal Working (AMB). The forum was organized by the<br />

Fraunhofer Institute for Manufacturing Engineering and Automation<br />

IPA in Stuttgart funded by the Federal Ministry of<br />

Education and Research (BMBF).<br />

The manufacturing chain of the<br />

cutting tool industry<br />

Today, cutting tools are predominantly made of composite<br />

materials, preferably hard metals based on tungsten carbide.<br />

Here, powder metallurgy is today’s state of the art<br />

process via high temperature pressing and sintering [1,2,3] .<br />

The sequence of operations typically involved in a powder<br />

metallurgy process is depicted schematically in figure 1.<br />

The process utilizes metal powder that is mixed with a<br />

binder into a feedstock [4] which is then compacted into<br />

green parts through a molding and pressing process and<br />

sintered to bond the particles together [5] . This manufacturing<br />

process allows for the production of simple geometries<br />

as well as near net shape geometries such as indexable inserts<br />

[2] . For more complex geometries as is the case with<br />

milling tools for example, further machining operations<br />

need to be applied with geometrically undefined cutting<br />

edges by means of high hardness abrasive grinding [1,2,6] .<br />

This process is time and cost consuming and limits the design<br />

freedom of the inner and outer cutting tool structures<br />

significantly [1,2] . While macro-geometric features like chip<br />

flute geometry are limited by both the shape and kinetics<br />

of the grinding tool, the integration of internal tool structures<br />

such as internal coolant channels is impossible or<br />

requires considerable efforts [2] .<br />

During the last decade, suitable Additive Manufacturing<br />

technologies (AM) have emerged, however, that provide<br />

the opportunity to manufacture individual components<br />

with a high degree of design freedom. These technologies<br />

like Selective Laser Sintering (SLS) are based on<br />

powder bed fusion and use a laser to selectively solidify<br />

the powder. Figure 2 shows the manufacturing process. SLS<br />

gains the geometric information out of a 3D CAD model<br />

that is sliced into layers of a certain layer thickness [7] . The<br />

parts are then produced in a cyclic process. In a first step,<br />

powder is applied in layers to a retractable platform inside<br />

a building chamber. Subsequently, cross sections of the<br />

component to be manufactured are scanned and locally<br />

fused by the energy input of a laser beam and solidified.<br />

In the last step of the cycle, the building platform is lowered<br />

by one layer thickness before a roll applies new powder<br />

on top of the previous layer. The sequence of powder<br />

figure 1<br />

Steps of the powder metallurgy process [Fraunhofer IPA]<br />

36 no. 1, <strong>2020</strong>, March

processes<br />

figure 2<br />

Schematic of the selective laser sintering process, according to [4]<br />

application, exposure and lowering of the platform is repeated<br />

until the three-dimensional object has been built<br />

up layer by layer [8,9] .<br />

Additive manufacturing as enabler<br />

for lightweight construction and<br />

functional integration<br />

Especially Selective Laser Sintering as one of different Additive<br />

Manufacturing technologies is gaining ground as an<br />

alternative to conventional manufacturing because it offers,<br />

among other benefits, shape complexity, weight optimization<br />

and functional integration for near net-shape<br />

products. Moreover, AM offers a great potential to achieve<br />

time- and cost-efficiency and to further reduce the need<br />

for post-processing [2,8] .<br />

Further potential for cutting tool manufacturers<br />

arises from the generative design of hollow<br />

structures and the possibility of functional<br />

integration. Thus, the static and dynamic behavior<br />

[2] of cutting tools can be optimized<br />

through targeted mass and stiffness distributions,<br />

as can be seen from the example of the<br />

laser-sintered external reamer by MAPAL, illustrated<br />

in figure 3. A ribbed structure inside<br />

the tool enables weight optimization of over<br />

50 %, which leads to a significant increase in<br />

productivity with the associated increase in<br />

cutting speed. The internal cavities also ensure<br />

an almost perfect concentricity of the<br />

rotary tool due to the optimized mass distribution,<br />

so that machining can be carried out<br />

with higher accuracy [13] .<br />

The geometric freedom to design internal<br />

structures such as freeform “drilling” holes<br />

also permits the integration of new cooling<br />

concepts. The indexable insert drill constructed<br />

additively by MAPAL uses a cooling concept<br />

with spiral cooling channels whose AMgenerated<br />

triangular shape deviates from the<br />

conventional circular shape thus offering considerable advantages.<br />

As compared to a central coolant duct, the use of<br />

such a cross-section allows the surface moment of inertia<br />

and the coolant flow rate to be significantly optimized. In<br />

addition, the specific cooling channel profiles, which run<br />

parallel to the chip flute, increase the core stability [14] .<br />

An example of how geometric variability can improve<br />

cutting tool functionalities is the polycrystalline diamond<br />

(PCD) screw-in milling cutter developed by the Komet<br />

Group. Its additively manufactured body, equipped with<br />

PCD blades, is screwed onto a tool holder. The additive<br />

procedure permits a modified arrangement of the cutters<br />

as well as larger axis angles whereby more PCD blades can<br />

be placed on the cutting tool leading to significant productivity<br />

gains [10] . As far as flute geometries are concerned,<br />

AM also permits greater freedom with regard to external<br />

contours. The Komet Group has developed a PCD-drilling<br />

tool which, thanks to generatively manufactured filigree<br />

chip spoilers, prevents chip deposition both in the workpiece<br />

and the chip flute [11] . While the chip space of conventional<br />

boring tools is open to the side and to the front,<br />

the chip spoiler on each cutter covers the flute frontally<br />

and radially. This leaves a gap of only a few millimeters<br />

between the chip spoiler and the tool cutting edge,<br />

through which the resulting chip flows off and is safely<br />

guided out of the bore via the spoiler channel [11,12] .<br />

figure 3<br />

The AM-generated rib structure inside the<br />

external reamer enables a significant weight reduction<br />

[MAPAL Dr. Kress KG]<br />

Economic potential and technological challenges<br />

in AM for cutting tool manufacturing<br />

The use of additive processes in the manufacture of cutting<br />

tools is economically feasible due to their ability to<br />

produce highly individualized components, especially<br />

for prototype construction, special tools and small batch<br />

sizes. Hybrid strategies that combine additive and metalcutting<br />

manufacturing processes can be used to increase<br />

economic efficiency even with higher quantities: Simple<br />

no. 1, <strong>2020</strong>, March<br />


processes<br />

areas such as the basic tool body are manufactured conventionally,<br />

while more complex areas with integrated<br />

functions are built up additively [14,15] .<br />

Desiderates for future applications of additive processes<br />

in cutting tool manufacturing lie particularly in the field<br />

of material development. In addition to ceramics, some<br />

metallic materials such as tungsten carbide can already<br />

be processed as additives for limited areas of application,<br />

for example in mold making and for tools used in forming<br />

technology [16,17] . However, the existing additive processes<br />

in the field of solid carbide tools are still proving to be unsuitable,<br />

since cutting edges that are able to withstand the<br />

high mechanical requirements cannot currently be produced<br />

in sufficient quality using additive processes [2,17] .<br />

Conclusion<br />

The term Additive Manufacturing represents different<br />

technologies that build components layer by layer via<br />

digital information using diverse materials such as metals<br />

or plastics. Since AM requires no individual tools or fixtures,<br />

it is particularly suited for rapid prototyping, special<br />

tools and small lot sizes. From an economical and technological<br />

perspective, crucial advantages are an increased<br />

design freedom, including the ability to exploit topology<br />

optimization for lightweight applications. Moreover, AM<br />

has the ability to incorporate added functionality such as<br />

internal cooling channels and provides highly complex geo<br />

metries like hollow structures beyond the limits of conventional<br />

manufacturing. Reducing the lifecycle time between<br />

concept, design and actual manufacture makes the additive<br />

processes economically feasible. To exploit the innovative<br />

potential of AM beyond existing solutions, further<br />

research needs to be undertaken with regard to upstream<br />

and downstream processing steps and the enhancement of<br />

varied application scenarios. From today’s view, AM is an<br />

interesting technology with regard to the tool body – for<br />

application in the field of “cutting edges”, further technological<br />

developments must be realized.<br />

Literature<br />

[1] Friemuth, T. (2002):<br />

Herstellung spanender Werkzeuge. Postdoctoral thesis.<br />

in: Fortschrittberichte VDI: Reihe 2, Betriebstechnik 615 (2002)<br />

[2] Reuber, M.; Schwanekamp, T. (2016):<br />

Additive Herstellung von Zerspanwerkzeugen aus<br />

WC-Co-Hartmetall. Potentiale und Herausforderungen.<br />

in: Industrie 4.0 Management, 2016, 32(5), 12–16<br />

[3] Sossou, G.; Demoly, F.; Montavon, G.; Gomes, S. (2018):<br />

An additive manufacturing oriented design approach<br />

to mechanical assemblies<br />

in: Journal of Computational Design and Engineering<br />

5 (2018) 3-18. Accessible:<br />

https://doi.org/10.1016/j.jcde.2017.11.005<br />

[4] Kerns, J. (2016):<br />

Powder-Metallurgy Processes<br />

accessible: https://<br />

www.machinedesign.com/metals/powder-metallurgy-processes<br />

[5] Kumar, P.; Xavior, A. (2018):<br />

Processing of Graphene/CNT-Metal Powder<br />

accessible: http://dx.doi.org/10.5772/intechopen.76897<br />

[6] Riedel, R.; Chen, I.-W. (2008):<br />

Ceramics Science and Technology<br />

volume 1: Structures, WILEY-VCH Verlag<br />

[7] Poprawe, R. (2011):<br />

Tailored Light 2. Laser Application Technology.<br />

in: Springer Verlag<br />

[8] Klahn, C.; Leutenecker, B.; Meboldt, M. (2014):<br />

Design for Additive Manufacturing – Supporting the<br />

Substitution of Components in Series Products<br />

in: Procedia CIRP 21 (2014) 138-143<br />

[9] Reiff, C.; Wulle, F.; Riedel, O.; Epple, S.; Onuseit, V. (2018):<br />

On Inline Process Control For Selective Laser Sintering<br />

in: 8th International Conference on Mass Customization and<br />

Personalization – Community of Europe, 19-21<br />

[10] KOMET-GROUP (2017):<br />

Additive Herstellverfahren erzeugen<br />

leistungsfähigere Fräser und Bohrer<br />

accessible: https://mav.industrie.de/fertigung/werkzeuge/<br />

aus-ideen-wachsen-werkzeuge/<br />

[11] Gillhuber, A. (2017):<br />

Filigraner Spänespoiler verhindert<br />

Spanablagerungen im Bauteil<br />

accessible: https://www.maschinenmarkt.vogel.de/filigranerspaenespoiler-verhindert-spanablagerungen-im-bauteil-a-576145/<br />

[12] KOMET-GROUP (2017):<br />

Bohrwerkzeug mit Spänespoiler<br />

accessible: https://www.kometgroup.com/presse/produktedienstleistungen/detail/bohrwerkzeug-mit-spaenespoiler/<br />

[13] Leichtbau BW GmbH (2016):<br />

Leichte Außenreibahlen sorgen für Produktivitätszuwachs –<br />

Neue Designmöglichkeiten durch selektives Laserschmelzen<br />

halbieren Gewicht des Werkzeugs der MAPAL Dr. Kress KG<br />

accessible: https://www.leichtbau-bw.de/fileadmin/_migrated/<br />

news_uploads/PM_ThinKing_Januar_Mapal.pdf<br />

[14] Doris (2015):<br />

Mapal setzt auf additive Fertigung für<br />

Schneidplattenbohrer der QTD-Serie<br />

accessible: https://3druck.com/pressemeldungen/mapal-setzt-aufadditive-fertigung-fuer-schneidplattenbohrer-der-qtd-serie-3636310/<br />

[15] Kress, J. (2017):<br />

Wir zögern nicht, neue Technologien einzuführen<br />

accessible: https://industrieanzeiger.industrie.de/technik/fertigung/<br />

wir-zoegern-nicht-neue-technologien-einzufuehren/<br />

[16] Fraunhofer IKTS (2018):<br />

Extrem hartes Hartmetall aus dem 3D-Drucker<br />

accessible: https://additive.industrie.de/news/extrem-harteshartmetall-aus-dem-3d-drucker/<br />

[17] Reuber, M.; Schwanekamp, T. (2018):<br />

Vollhartmetallwerkzeuge additiv herstellen<br />

in: Technische Rundschau, 2018, 68–70<br />

further information: www.ipa.fraunhofer.de<br />

38 no. 1, <strong>2020</strong>, March

processes<br />

Medical technology<br />

Efficient processing for the benefit of<br />

customers and patients<br />

TYROLIT presented the latest updates<br />

in medi cal technology grinding applications<br />

at COMPAMED 2019 in Düsseldorf, Germany.<br />

The leading manufacturer is focusing among<br />

other things on core technologies for knee joint<br />

grinding.<br />

The trend of an ever-aging society has increasingly<br />

brought medical advancements and medical technology<br />

into the spotlight. At the same time, the demand for “spare<br />

parts” and implants for the human body is increasing in<br />

order to maintain the quality of life into old age.<br />

Due to the requirements for precision and small tolerances<br />

in this industry, manufacturers look to their reliable<br />

and experienced partners. Continuous innovations for<br />

over 100 years has enabled TYROLIT to keep its finger on<br />

the pulse of time.<br />

Their new lightweight core made of natural fibres<br />

allows for a significant weight reduction in knee joint<br />

grinding. The N-LW (natural lightweight) core is not<br />

only lighter and more cost-effective, but also offers positive<br />

damping characteristics.<br />

In grinding femur components<br />

the use of superabrasive grinding<br />

tools is the industry standard<br />

and TYROLIT manufactures<br />

a double-layered disc<br />

with a high wheel rim that can<br />

be used for processing over the<br />

full 20 mm.<br />

TYROLIT offers a selection of grinding and polishing<br />

sleeves for the machining of hip joints. At COMPAMED<br />

they presented their range of various resin and vitrified<br />

bonded grinding tools. The productivity of the manufacturing<br />

process can be increased by using conventional or<br />

superabrasive grinding tools adapted to the respective application.<br />

For example, the cycle times for pre-grinding<br />

could be reduced from 10 to 1 minute.<br />

A third pillar of their medical technology portfolio is<br />

the processing of surgical instruments. An updated range<br />

of grinding and polishing tools from TYROLIT is used for<br />

a variety of finishing processes. For more safety during<br />

surgical procedures, scalpels are<br />

sharpened with TYROLIT COOL<br />

CUT discs and finished with elastic<br />

tools, thus guaranteeing the highest<br />

surface quality.<br />

further information: www.tyrolit.group/de/<br />

no. 1, <strong>2020</strong>, March<br />


processes<br />

CBN generating grinding<br />

A thoroughly economic alternative<br />

The demand for high quality gear teeth in<br />

areas such as electric mobility, for example,<br />

come with great challenges. Liebherr is working<br />

on the development of solutions for economic<br />

manufacturing.<br />

For many applications, generating grinding with corundum<br />

is a good solution, but this abrasive also has certain<br />

disadvantages for some applications. Grinding special geometrical<br />

modifications could, for example, have a negative<br />

effect: The modifications would then have to be integrated<br />

in the tool completely or partially via the dressing process<br />

in the machine. On one hand, however, profiling a grinding<br />

worm needs time and, on the other, it alters the geometry<br />

of the tool. Depending on the choice of grinding<br />

process, it has to be repeated in very short intervals in<br />

order to guarantee the production at the same level of<br />

quality. This is just where Liebherr comes in, offering a<br />

CBN tool with an implemented modification and demonstrating<br />

on an example workpiece that extremely economic<br />

production is possible with these tools.<br />

CBN stands for cubic boron nitride. Next to diamond,<br />

it is the second hardest cutting material in the world. It<br />

consists of a three-dimensional matrix made of boron and<br />

nitrogen atoms that can develop a broader spectrum of<br />

crystal forms than diamond. It has high thermal conductivity<br />

and a low coefficient of friction. In this way, the<br />

workpiece heats up much less than grinding with corundum,<br />

for example. It is possible to machine very hard materials<br />

reliably with CBN. CBN grinding worms can also<br />

be smaller, which means that the range of applications is<br />

greater than with corundum.<br />

to the limited shift possibility, which in turn raises tool<br />

costs and also cycle times. It may be possible on corundum<br />

tools (e.g. for distortion-free generating grinding) to<br />

increase the workpiece number for each dressing interval<br />

through new mathematical solutions but this also applies<br />

in the same way to the use of CBN tools.<br />

With CBN, the dressing times can be dispensed with<br />

completely, which means that cycle times and thereby<br />

manufacturing costs can be reduced. CBN is highly<br />

machinable and generates an extremely low measuring<br />

complexity. A CBN grinding worm is clamped in and<br />

the grinding process begins straightaway - with no need<br />

at all to make corrections beforehand. The unit costs of a<br />

test workpiece (m = 1.53 mm, z = 81 mm) included a special<br />

width modification with corundum at 4.25 Euros with<br />

a cycle time of 114.6 seconds, while the same grinding process<br />

with CBN was 3.38 Euros cheaper and considerably<br />

faster with a cycle time of 78 seconds. Where the number<br />

of producible workpieces per dressing cycle with corundum<br />

is in the two figure range, it can occasionally reach<br />

well into the four figure range with a CBN coating. “Each<br />

situation needs to be assessed individually to determine<br />

which grinding worm is the most viable. We are happy<br />

to advise our customers on whether CBN is the better<br />

alternative for their numbers and application scenarios”,<br />

offers Andreas Mehr.<br />

A robust process<br />

In a dressing-free CBN process, all parameters are predefined<br />

and “frozen”. This is a crucial difference between<br />

corundum and CBN processes: All corundum processes<br />

are subject to changes through dressing, which can impair<br />

CBN stands for short cycle times and<br />

long tool life<br />

CBN tools are currently experiencing a comeback. They<br />

may be expensive to procure but make gains with the<br />

unit costs on modifications. Dr. Andreas Mehr, the leading<br />

grinding technology expert at Liebherr-Verzahntechnik<br />

GmbH with a PhD in engineering, explains the differences<br />

of the grinding materials: “We have been using galvanically<br />

coated CBN since 1988. It is a highly durable<br />

grinding material. A significant increase in the grinding<br />

performance of modern corundum has been achieved in<br />

recent years but, compared with CBN, it comes with the<br />

disadvantage of the amount of effort required for dressing,<br />

which is encountered most prominently on topological<br />

grinding processes.” With these processes, the number of<br />

workpieces per dressing cycle is significantly reduced due<br />

CBN generating grinding - a thoroughly economic alternative<br />

40 no. 1, <strong>2020</strong>, March

processes<br />

the grinding worm quality. Examples are wear of the dressing<br />

tool or diminishing worm diameter: As the worm diameter<br />

diminishes, the length of the active worm spirals<br />

are shorter, which reduces the number of active abrasive<br />

grains. A consequence of this is an increase in the roughness<br />

factor on the tooth flank, which should remain constant<br />

throughout the worm tool life. “There is a limit to<br />

which this can be counteracted through finer dressing processes,”<br />

explains Andreas Mehr.<br />

Additional processes, such as dressing, present fault sources<br />

that simply cannot occur with CBN. CBN processes<br />

are extremely robust and quality assured, which makes<br />

them particularly interesting for the economic production<br />

of high quality gear teeth, such as in the area of electric<br />

mobility. “Attempts are being made to reduce noise, particularly<br />

on the very sophisticated electric gears in the<br />

automotive sector, by changing the macro and micro geometry,”<br />

explains the expert.<br />

Liebherr manufactures CBN tools at the Ettlingen factory.<br />

“Our aims in production are high performance and<br />

top quality in a very sturdy process”, explains Haider<br />

Arroum, regional Sales Manager for gear cutting tools.<br />

The production of CBN grinding worms and discs is<br />

ütherefore carried out in a closed loop process in which<br />

measurement results flow immediately back into the production<br />

para meters as corrections. “We have to carry over<br />

the configu ration accuracy to manufacture as close to 1:1<br />

as possible”, says Haider Arroum in substantiating the<br />

complicated procedure.<br />

GrindTec <strong>2020</strong>, hall 3, booth 3029<br />

LGG 180 with integrated centrifuge<br />

LGG 180 with integrated centrifuge<br />

In most cases, the new generation of electric cars is built in new factories where the focus is on reliable and<br />

clean processes. At EMO 2019, therefore, Liebherr exhibited a generating gear grinding machine that meets the<br />

requirements of a clean factory in full: The LGG 180 with integrated centrifuge. The centrifuge station for the<br />

removal of burrs and coolants is located at the pocket of the ring loader pointing towards the operator side. It<br />

is mounted decoupled from the machine so that oscillations or vibrations from the centrifugation process do<br />

not have any effect on the gear quality. Spinning during the machining process is therefore possible. There is<br />

no loss of oil, the media remain in the machine and the cleaned components can be transported further in any<br />

automation system.<br />

Advantages of integrated centrifuge unit:<br />

t clean factory thanks to integrated centrifuge: dry workpieces, no oil loss, reliable production<br />

t decoupled centrifuge unit with no transfer of vibrations to grinding machine<br />

t can be connected to any conventional automation solution<br />

Advantages of CBN tools:<br />

t tool mounting, pre-profiling and dressing are dispensed with<br />

t no adjustment of profile angle necessary<br />

t easy operation<br />

t significantly reduced measuring and testing effort<br />

further information: www.liebherr.com<br />

no. 1, <strong>2020</strong>, March<br />


processes<br />

Cutting narrow incisions with ultra-high precision<br />

in high density materials<br />

Fine abrasive waterjet bridges the gap<br />

Waterjet cutting is a common method for<br />

processing parts in high density materials such as<br />

aluminum, stainless steel, titanium and carbon<br />

composites. The FAWJ cutting process bridges<br />

the gap between micro laser and EDM cutting and<br />

brings water jet cutting into the field of micro<br />

part processing.<br />

To enable such levels of precision you need two things:<br />

- a cutting head and cutting process for FAWJ cutting,<br />

and<br />

- a machine built for extreme accuracy.<br />

The NCM 10 Micro from Water Jet Sweden fulfils both of<br />

those requirements.<br />

FAWJ cutting process for 0.2 mm incisions<br />

The first micro waterjet cutting head was developed by<br />

Water Jet Sweden in 2008. It is a high precision cutting<br />

tool producing one of the most precise abrasive water jets<br />

in the world. The unique cutting head enables an abrasive<br />

jet diameter down to 0.2 mm. The FAWJ cutting process<br />

requires very fine abrasives of 230-240 mesh and a special<br />

CNC controlled dosage abrasive feeder.<br />

Machine table designed for ± 0.008 accuracy<br />

To reach the levels of accuracy required in micro part manu -<br />

facturing, the NCM 10 water jet has a number of unique<br />

design features to create a rigid table that withstands temperature<br />

fluctuations:<br />

Mineral Casting Bearlit table frame - a table frame made<br />

of a composite material with exceptional stiffness that<br />

withstands vibrations and temperature fluctuations.<br />

The frame is integrated in the machine construction<br />

and motion system as a complete unit.<br />

Rubber suspended stainless steel water catcher - the<br />

free-standing catcher solution prevents vibrations and<br />

temperature variations from influencing the cutting<br />

process. Stainless steel makes it maintenance free.<br />

Renishaw Invar Scale in X and Y - with a Renishaw<br />

Absolute Linear Encoder fitted in both X and Y axes<br />

you have a micrometer scale with an extremely low<br />

expansion coefficient and ultra-high resolution.<br />

Prepared for any kind of fixtures<br />

The palettized cutting table makes it easy to install fixtures<br />

and presses for different types of machining. Maximum<br />

table size is 1x1 m which covers most cutting applications.<br />

The cutting table is fixed into the table frame to<br />

enable ultra-high precision cutting.<br />

“There are many suppliers who state that they offer<br />

micro cutting machines, but not many can offer a true<br />

micro part cutting tool with 0.2 mm incision combined<br />

with ± 0.008 accuracy,” says Tony Rydh, co-founder and<br />

CTO at Water Jet Sweden.<br />

Fine abrasive waterjet cutting vs. EDM<br />

Extruder tool matrix<br />

tempered tool steel,<br />

15 mm<br />

max. speed<br />

min. speed<br />

cutting accuracy<br />

manufacturing time<br />

prime cost<br />

NCM 10<br />

11 mm/min<br />

4 mm/min<br />

0.02 mm<br />

1.30 hours<br />

180 Euro<br />

EDM<br />

1 - 2 mm/min<br />

about 0.001 mm<br />

> 8 hours<br />

480 Euro<br />

Micro part<br />

Fine abrasive waterjet - laser<br />

further information: www.waterjetsweden.com<br />

42 no. 1, <strong>2020</strong>, March

machining center<br />

Full-line supplier VOLLMER<br />

introduces its key trio<br />

All good things come in threes; and the<br />

trade fair appearance of sharpening specialist<br />

VOLLMER at GrindTec <strong>2020</strong> will emphasise this<br />

by presenting itself in Augsburg for the first time<br />

as a full-line supplier.<br />

The three consecutive L’s of the term “full-line supplier”<br />

symbolise the three technologies of grinding, eroding and<br />

laser machining with which the machine manufacturer<br />

can completely cover the machining of rotary tools, circular<br />

saws and band saws. The three L’s also resemble the 111<br />

years during which the traditional Swabian company has<br />

been successful on the international market of sharpening<br />

technology since 1909. With laser technology, VOLLMER<br />

is becoming a full-line supplier<br />

As a leading technology and service company, VOLLMER<br />

develops sharpening machines and automation options for<br />

precisely machining cutting tools made from carbide and<br />

tipped with PCD (polycrystalline diamond). VOLLMER's<br />

latest innovation is the exciting new VLaser 270 laser machine.<br />

The machine will be introduced to visitors for the<br />

first time <strong>2020</strong>, March 18th to 21st, and will be one of the<br />

full-line supplier's trade fair highlights. Using the power<br />

of the laser light and linear drive technology, PCD-tipped<br />

tools can be precisely machined with the VLaser 270.<br />

Around a dozen grinding and<br />

erosion machines on view<br />

VOLLMER will be bringing around a dozen sharpening<br />

machines and automation solutions to GrindTec that<br />

relate to eroding and grinding technology. The VPulse 500<br />

and QXD 250 wire erosion and disc erosion machines<br />

will be on show, just like the VHybrid 360 combined<br />

grinding and erosion machine. Tool manufacturers can<br />

use the VHybrid 360 to both grind and erode carbide and<br />

PCD tools such as drills, milling cutters or reamers in a<br />

single set-up. Three models from the VGrind family will be<br />

on show in Augsburg: The VGrind 360E basic model, the<br />

VGrind 360 and the VGrind 340S with linear drive for machining<br />

extremely small carbide tools. With two new optional<br />

features, the VGrind 360 optimises productivity for<br />

tool manufacturers. Due to a higher processing speed, the<br />

material removal rate can be significantly increased whist<br />

the simultaneous re place ment of grinding wheels and<br />

tools significantly reduces non-productive time.<br />

Machines for machining carbide-tipped circular saw<br />

blades are traditionally well- represented at the VOLLMER<br />

GrindTec stand. On the global grinding technology market,<br />

the VOLLMER machines abbreviated as CHX, CHP,<br />

CHF and CHD are some of the industry’s best-selling<br />

technology. Whether in production or resharpening - the<br />

completely automated and CNC-controlled sharpening<br />

machines can be found wherever wood, metal, aluminium<br />

or plastic have to be cut to a precise size with circular saws.<br />

Service package and digital services<br />

At GrindTec VOLLMER will also be providing information<br />

regarding its service package for training, finance, maintenance<br />

and repair. With the digital initiative V@dison, the<br />

full-line supplier brings together applications for Industry<br />

4.0 and IoT (Internet of Things) to connect people and machines.<br />

The “Visual Support” app provides an innovative<br />

new access path, which offers VOLLMER customers the<br />

opportunity to connect directly with the VOLLMER help<br />

desk. Installed on a smartphone or tablet, the app supports<br />

the machine operator online, allowing them to take<br />

and exchange live pictures of a machine using the video<br />

function. VOLLMER will also be explaining how end users<br />

can connect various machines with each other via the<br />

IoT “umati” platform. The umati platform is based upon<br />

the OPC UA protocol that was developed by the German<br />

Machine Tool Builder's Association (VDW), together with<br />

around 50 machine manufacturers.<br />

GrindTec <strong>2020</strong>, hall 1, booth 1006 and 1027<br />

At GrindTec <strong>2020</strong>, VOLLMER will be presenting itself for the first<br />

time as a full-line supplier for machining tools, circular saws and<br />

band saws, and will be showcasing machines that use the three<br />

sharpening technologies grinding, eroding and laser machining<br />

further information: www.vollmer-group.com<br />

no. 1, <strong>2020</strong>, March<br />


machining center<br />

The easy route to<br />

production autonomy<br />

More efficient grinding processes thanks to connected solutions<br />

Autonomous, resource-saving, zero-defect production<br />

- who doesn't want that? Many companies<br />

are pushing concepts to achieve this goal, but at<br />

GrindTec <strong>2020</strong> Rollomatic SA will be showcasing<br />

realistic solutions designed especially for tool<br />

grinding. The focus here is on a smart-factory infrastructure,<br />

new, high-precision grinding and laser<br />

machines and a comprehensive training program<br />

covering all aspects of tool grinding.<br />

The smart factory, autonomous production, the Internet of<br />

Things: technologies that once appeared to belong in the<br />

realm of the visionary are now finding their way into production<br />

halls. And some of them are arriving on the scene<br />

more quickly than you realize, as inventive developers set<br />

about turning the fruits of their innovations into marketready<br />

products. “We have systematically devoted ourselves<br />

to this field for many years, which means that we now<br />

enjoy that all-important technological edge. We are extremely<br />

proud to showcase this at GrindTec <strong>2020</strong>, where<br />

visitors will have the opportunity to experience fully automated<br />

tool production up close and witness the grippers of<br />

our NEXTAGE robots in action,” said Damien Wunderlin,<br />

head of Sales at Rollomatic SA in Le Landeron, Switzerland.<br />

The smart factory demonstrates the perfect production<br />

environment of the future; at GrindTec <strong>2020</strong>, Rollomatic will<br />

showcase a range of highly viable solutions that can be deployed<br />

without problems by almost any tool manufacturer<br />

Rollomatic offers solutions, not just concepts<br />

Continuous data analysis, status monitoring, automated<br />

and monitored processes, cooperation with industrial<br />

robots - these are the challenges that the factory of the<br />

future will face. But thanks to Smart Connectivity Solutions<br />

from Rollomatic, these challenges can be much more easily<br />

addressed in the field of tool manufacturing.<br />

Thanks to linear motors<br />

and hydrostatic technology,<br />

the GrindSmart® 830XW<br />

has optimized production<br />

processes in many factories;<br />

users benefit from perfect<br />

surface and cutting edge<br />

qualities<br />

At GrindTec <strong>2020</strong>, Rollomatic will provide an impressive<br />

demonstration and showcase of the solutions it has developed<br />

to tackle these future challenges. “We will be de monstrating<br />

the standard production process in a tool making<br />

plant. The ShapeSmart ® NP50 cylindrical grinding<br />

machine and GrindSmart ® 630XW3 grind the blanks and<br />

the complete tools. They are then measured and packaged<br />

ready for dispatch, and the necessary labels are affixed<br />

to the packaging - just like in regular production, except<br />

that the work is performed in cooperation with two of our<br />

NEXTAGE robots,” says Damien Wunderlin.<br />

A new machine harmony<br />

In addition to the robots working hand in hand, the two<br />

grinding machines also “understand” each other: the<br />

ShapeSmart ® NP50 - the latest addition to the cylindrical<br />

grinding tool series - promises even greater flexibility, faster<br />

configuration and improved surface qualities. It covers<br />

a wide range of diameters from 0.025 mm to 25.0 mm,<br />

which opens up unlimited possibilities even for more unusual<br />

length-to-diameter ratios. And the patented Smart<br />

Punch process opens up myriad possibilities when it comes<br />

to cylindrical grinding: the ShapeSmart ® NP50 can even<br />

process complex shapes and out-of-round punches with<br />

no problems.<br />

This production duo is complemented by the new six-axis<br />

tool grinding machine GrindSmart ® 630XW3. Thanks to<br />

its expanded, ultra-compact grinding wheel changer for 16<br />

wheels (including coolant distributors), it is ideally adapted<br />

for unattended operation. This simplifies process management<br />

and significantly reduces non-productive times. Linear<br />

motors and a torque motor on the rotating axis ensure<br />

improved surface qualities and reduce maintenance costs.<br />

44 no. 1, <strong>2020</strong>, March

machining center<br />

Laser machining with added value - the LaserSmart 510 is not<br />

only extremely fast, but also offers the option to sharpen<br />

carbide endmills with CVD coating<br />

Dream surface qualities!<br />

When it was unveiled, it caused a sensation: The completely<br />

redeveloped six-axis GrindSmart ® 830XW was the<br />

first tool grinding machine to combine the benefits of<br />

linear motors on x-, y- and z-axes with hydrostatics. The<br />

product was impressive not only on paper but also in practice,<br />

as proven by the positive feedback from users who<br />

deployed this exceptional tool and cutter grinder in production.<br />

Damien Wunderlin: “Our goal was to further<br />

reduce friction within the machine and ensure near-zero<br />

wear. We have eliminated residual friction by combining<br />

this with a hydrostatic system and effectively dampened<br />

vibrations. And, judging by the feedback from our customers,<br />

it seems that our approach has worked. The concept<br />

offers longer lifetime of the grinding wheels, produce<br />

perfect surfaces and cutting edges and, above all, ensure<br />

highly stable production processes - a key USP in the highquality<br />

segment.”<br />

A longer life thanks to a sharp CVD edge<br />

The one virtue of diamonds that machinists love but that<br />

can cause headaches for tool manufacturers is their hardness.<br />

While the geometry variants in PCD-equipped or<br />

CVD diamond tools were rather restricted due to the hardness,<br />

this field is being explored again since the launch of<br />

the LaserSmart 510, the latest-generation laser cutting machines<br />

from Rollomatic. The laser opens up undreamedof<br />

possibilities such as extremely sharp cutting edges with<br />

radii of 0.001 mm or less. This highly productive technology<br />

delivers outstanding quality and can speed up machining<br />

times fourfold. “The fact that our machine completes<br />

the entire process in a single step saves time and significantly<br />

increases productivity,” said Sven Peter, laser<br />

product manager at Rollomatic. “While it used to be almost<br />

impossible to create sharp and defined cutting edges<br />

on CVD-coated hard metal tools with repeat accuracy, this<br />

is no longer a problem thanks to our new lasering technology.<br />

This opens up entirely new application fields for this<br />

type of tool.”<br />

Well trained, optimally operated<br />

It is not the grinding machines alone that ensure efficiency<br />

and highly desirable tools, but first and foremost the people<br />

who design these tools and deploy them highly effectively<br />

on the Rollomatic machine. “Since it is becoming increasingly<br />

difficult to find high-quality, skilled personnel, we<br />

have launched a comprehensive, modular tool grinding<br />

training program,” says Damien Wunderlin. As part of this<br />

program, Rollomatic offers numerous courses each year<br />

con ducted by highly qualified, multilingual experts, both<br />

on the customer's premises as well as at its training centers<br />

in Switzerland, the USA, Japan, Taiwan, Thailand and<br />

China. The courses cover everything from grinding and<br />

maintenance to lean production, laser technology and robotics.<br />

Whether GrindSmart ® , GrindSmart ® Nano, Laser-<br />

Smart or ShapeSmart ® , special learning units and qualification<br />

levels have been created for all Rollomatic types.<br />

“This means that everyone gets their money's worth, whatever<br />

their level of knowledge. Our specialists have shown<br />

many an expert operator who thought they knew ‘their’<br />

machinery inside and out lots of little tricks that have occasionally<br />

led to a decisive breakthrough in tool design or<br />

the grinding process,” states Damien Wunderlin happily.<br />

A visit with added value<br />

Rollomatic has developed an impressive portfolio of tool<br />

grinding solutions as well as innovations in laser technology<br />

and cylindrical grinding. “Fast-moving sales markets,<br />

new competitors and personalized products require more<br />

flexible production systems - and a faster response to customer<br />

requirements. This is why we have created a complete<br />

package focusing on outstanding precision and value.<br />

By combining these products with smart automation solutions,<br />

customers can now build a production environment<br />

that is autonomous and highly efficient and delivers ultrahigh<br />

quality,” says Damien Wunderlin.<br />

GrindTec <strong>2020</strong>, hall 5, booth 5077<br />

The ShapeSmart®NP50 cylindrical grinding machine offers<br />

greater flexibility, faster configuration and improved surface<br />

qualities. It can also be easily connected to other Rollomatic<br />

grinding machines to form a “smart factory network”<br />

further information: www.rollomaticsa.com<br />

no. 1, <strong>2020</strong>, March<br />


machining center<br />

Jeremy Bunting, founder of Facet Precision Tools,<br />

talks about his company and its investment<br />

in ANCA machines<br />

Growing up in the cutting tool industry<br />

Jeremy Bunting, Managing Director of<br />

Facet Precision Tool grew up in the cutting tool<br />

industry, getting a hands-on education from<br />

a young age and then using this experience to<br />

start his own business. From laying out a brandnew<br />

manufacturing centre; to shaping and promoting<br />

Facet’s reputation; to training up a high<br />

performing team who are passionate about the<br />

craft of cutting tools - Jeremy has built the foundations<br />

for success.<br />

Jeremy begins: “I started designing my first tools at age<br />

14 in America as part of<br />

the family business, using<br />

manual grinding as well as<br />

conventional grinding to<br />

manu facture tools. After<br />

that I moved on to the applications<br />

side - getting exposure<br />

to feeds and speeds<br />

and eventually moved to<br />

Europe. In Europe I worked<br />

for different <strong>tooling</strong> manufacturers,<br />

seeing dif ferent<br />

approaches to manufacturing<br />

and precision <strong>tooling</strong>.”<br />

“I started Facet Precision Tools in 2015 primarily to service<br />

the aerospace and automotive sectors. Both these<br />

markets require special tools with distinct needs. At Facet<br />

we produce PCD, carbide cutting and coated carbide tools<br />

through distributers and direct to customers. Based in<br />

Germany we sell locally as well as to France, England and<br />

Spain. Through distributers we service Africa, Sweden,<br />

Turkey, Hungary, Austria, Italy and Mexico.”<br />

“It's challenging starting a new business. We had products<br />

in mind and were in a unique position where we<br />

could decide if these are our target markets - what machinery<br />

and equipment do we need? I considered my<br />

past experiences in the industry and how can I apply any<br />

learnings to the future. When we entered the market, I<br />

wanted to have high quality equipment, robust manufacturing<br />

processes and be producing market leading cutting<br />

tools.”<br />

“Since opening we have been growing steadily, in fact<br />

last year we doubled our sales. As we expand we are looking<br />

at how we can attract more customers, consider if<br />

we need to add additional products and as many people<br />

in the industry experience - are always looking for<br />

good people.”<br />

Establishing grinding capabilities<br />

“After deciding on a shop floor blue print, we invested in a<br />

range of ANCA machines with two MX7 Linear’s, an FX7<br />

and an EDGe as well as other equipment. We use the MX7s<br />

primarily for automotive <strong>tooling</strong> as they work well when<br />

grinding tools with larger diameters of 20, 25 and 32. We<br />

also run a lot of pocket grinding for PCD cutting tools on<br />

this model. The MX7 has a lot of horsepower that allows<br />

us to grind these tools in a very stable way. We use the FX<br />

for high volume carbide <strong>tooling</strong>. As an extremely rigid<br />

and thermally dynamic, stable machine I can rely on it to<br />

grind highly repeatable cutting tools.”<br />

“On the MX7 we have an<br />

ANCA spindle speeder that<br />

allows us to achieve higher<br />

rpm. We worked with ANCA<br />

to adjust the software to be<br />

able to provide a better stable<br />

pocket and a more accurate<br />

pockets in our grinding<br />

process.”<br />

“On the EDGe we manufacture<br />

PCD tools. In the<br />

past couple years we have<br />

been developing PCD vein<br />

tools with our own blanks and cutting tool designs - working<br />

through and refining our processes. The EDGe has allowed<br />

us to have a high degree of accuracy when trying<br />

to grind a lot of the geometries. I found that as a process,<br />

erosion enabled the repeatability and the quality we were<br />

looking for. We also added a vision camera system on the<br />

EDGe, allowing for a quick inspection inside the machine,<br />

to get higher repeatability and better quality versus taking<br />

it out of the machine, and putting it back in.”<br />

“And then there is ANCA’s 3D Cimulator program. Up<br />

to 95 % of the designs and problem solving are done on<br />

the simulator; testing the grinding process, reviewing and<br />

modifying before you go into a machine. It is our strongest<br />

tool to increase efficiency and reduce waste and that<br />

is a major help to our profitability. For example, carbide is<br />

extremely expensive where you can be paying from 400<br />

Euros for a 32 mm standard rod.”<br />

“The simulator also shows estimated grinding times which<br />

has been a great tool for us to reduce cycle times. Last time<br />

it took us, for example, 20 minutes to make this tool, but<br />

after considering a new idea or different approach we can<br />

reduce that time to 18, 17 or even 15 minutes all through<br />

experimenting in a simulated grinding environment.”<br />

46 no. 1, <strong>2020</strong>, March

machining center<br />

“We have touch probes on all the machines that allow us<br />

to easily change wheel packs, qualify the wheel and start<br />

moving quickly. It also allows us to remove human error<br />

and ensures a higher finished quality. To be able to dress<br />

and probe the wheel, picking back up where you left off<br />

without having to change the set up is very advantageous.”<br />

“One of the main reasons we love the ANCA machines is<br />

because of the software. We have found it to be extremely<br />

flexible and at Facet we don't use a lot of the standard<br />

ANCA programs and designs and instead do a lot of our<br />

work in profile editor, changing angles and profiles to<br />

meet the tool designs that we need. My Dad always said<br />

that ANCA was a software company that built a machine.”<br />

Specials are a relationship business -<br />

requiring communication and trust<br />

“As we build our company we want to be known for quality.<br />

From the start we have been trying to build our reputation<br />

for offering high quality tools rather than just entering a<br />

market and throwing anything out there and seeing what<br />

sticks. We are methodical in our approach to manufacturing<br />

certain tools or entering a marketplace or approaching<br />

certain things. Even if this means we are a bit slower and<br />

more tactful.”<br />

“Just as important, is our responsiveness to the customer<br />

through deliveries and application support. These are the<br />

foundation of our company. We start by listening - what<br />

does the customer want to achieve, am I understanding<br />

their needs correctly? Then I consider how the product<br />

could be improved, can we make other recommendations.<br />

We turn that request into a tool design that is checked by<br />

the customer.”<br />

“In aerospace, a common misunderstanding is the need<br />

for standard tools. Tools for aerospace require different<br />

lengths, diameters and applications. There is also a high<br />

requirement for accuracy, in Europe for example, we find<br />

aerospace have applications that need to be measured to<br />

a couple of microns and use a variety of methodology to<br />

make holes in different materials. It is a challenge making<br />

a product meet quality standards while working across a<br />

range of material applications.”<br />

Building a team of craftspeople<br />

“I think working in speciality tools excites an element of<br />

craftsmanship. Every day is different, and you can take<br />

pride in your work, was it correct, was it to print. That is<br />

why we look for a person who is flexible, shows an ability<br />

to learn, grow, and absorb information.”<br />

“I train everybody in my plant like they've never seen<br />

a grinding machine before. We invest time to build their<br />

knowledge base to understanding the manufacturing and<br />

measuring equipment. Again, partially because we're into<br />

specials where every tool design is different, we don't have<br />

pre-written programs.”<br />

“I think one of the best characteristics of a toolmaker is<br />

an attention to detail. Often people can become over invested<br />

in the productivity side - how many parts can I get<br />

through, how fast can I get them through the line. I train<br />

my team to be focused on the quality of the tool first and<br />

productivity second. And to meet these expectations of<br />

quality you have to have a high attention to detail. Just<br />

as important is to develop your team to have a passion for<br />

grinding. The more passion someone has for the product,<br />

the more likely they are to stay. Teaching your employee<br />

how to make a better-quality tool feeds their creativity and<br />

teaches them it is ok to have your own approach and style.<br />

At Facet we have an open dialogue with our teams of why<br />

we do the things that we do.”<br />

“I think there will always be a need for niche and special<br />

products and that means more special cutting tools.<br />

That's one of the reasons why we were very comfortable<br />

moving into this industry. So as materials change - if it's<br />

more glass, carbon composites or aluminium - we're in<br />

a good position to move with the market and respond<br />

to those changes. I have established the foundations of<br />

Facet Precision Tools to be agile with design expertise,<br />

workforce skills and manufacturing capabilities. We can<br />

and do adapt and invest in the machinery or develop our<br />

knowledge so we can meet the markets’ changing needs<br />

rather than focusing on materials.”<br />

ANCA Europe GmbH: GrindTec <strong>2020</strong>, hall 7, booth 7045<br />

further information: www.anca.com<br />

http:// facetprecision.com<br />

no. 1, <strong>2020</strong>, March<br />


machining center<br />

Entering a demanding market niche<br />

HSC milling: highly productive, high-volume<br />

production for surgical instruments<br />

Surgical instruments are high-precision<br />

products that are manufactured with great care,<br />

usually in small quantities. The structures and<br />

equipment of manufacturers specializing in these<br />

products are therefore designed above all for a<br />

high level of flexibility in re<strong>tooling</strong>.<br />

A separate process chain should accordingly be set up for<br />

one-time products in large quantities. The key element is a<br />

two-spindle machine from Schwäbische Werkzeugmaschinen<br />

GmbH (SW) with very high repeat accuracy. An assess -<br />

ment report.<br />

“The requirements are high and the competition is hard<br />

in manufacturing of precision mechanical surgical instruments,”<br />

confirms Frank Pauschert, Regional Sales Manager<br />

of SW, Schwäbische Werkzeugmaschinen GmbH in Waldmössingen,<br />

Germany. His customers include a company<br />

in this sector that has grown from modest beginnings<br />

when it was founded in the 1980s to become a mid-sized<br />

enterprise, with about 130 employees. Currently about<br />

1,000 different utensils are manufactured for a wide range<br />

of surgical applications. All instruments come complete<br />

and ready for use. The individual parts are made of premium<br />

biocompatible materials such as stainless steel and<br />

are manufactured in machining processes. Despite the use<br />

of modern NC-controlled machine tools, manual operations<br />

make up a great deal of the manufacturing process<br />

for these instruments, because they consist of up to 40 different<br />

components that must be refined, surface-treated<br />

and assembled meticulously by hand. In addition, they are<br />

often manufactured with numerous variants. This necessitates<br />

small batch sizes and because of that, a prime requirement<br />

of the relevant manufacturing systems is very<br />

flexible re<strong>tooling</strong>. Due to the extraordinary diversity of<br />

variants, there is also no way to work from stock, thereby<br />

lowering costs by manufacturing in larger batches.<br />

Strategy for the future:<br />

a challenging one-time product<br />

Since the manufacturer has not previously produced any<br />

of its own products, it is constantly compared with the<br />

numerous competitor products already available in terms<br />

of price by customers, who often have great market power.<br />

This limits profitability and with it future growth possibilities.<br />

To safeguard the future in the long-term, a decision<br />

was made about two years ago to enter an extremely challenging<br />

large-scale production project: manufacturing of<br />

a one-time tool for neurosurgery that is used so often that<br />

hundreds of thousands of units are needed annually.<br />

It is a type of forceps made of aluminum that can be<br />

used to grasp tissue components while at the same time<br />

stopping minor bleeding with electrical pulses. Minute<br />

tubes were also integrated into each arm of the forceps<br />

through which an irrigation fluid can be directed into the<br />

operat ing area. Despite its straightforward appearance, the<br />

instrument requires very time-consuming manufacturing<br />

with numerous mechanical and manual work cycles,<br />

all of which must meet strict quality requirements. Many<br />

of these work cycles have to be carried out under a microscope.<br />

Setting up the process chain requires extensive<br />

devel opment efforts as well as investments in machines<br />

and special equipment. Additional employees are currently<br />

being hired and qualified for this purpose.<br />

A machining center with the power<br />

of a sports car<br />

The starting point and key element of the process chain is<br />

an automated dual-spindle BA 321 machining center from<br />

SW. The system has a working area of 300 x 500 x 375 mm<br />

per spindle. The spindles are equipped with an HSK A63<br />

interface and reach speeds of up to 17,500 rpm with a chipto-chip<br />

time of 2.5 s. The tool change system has a capacity<br />

of from 2 x 20 to maximum 2 x 60 slots.<br />

The automation unit consists of a supply unit for the press-drawn<br />

sections and a drawer for depositing parts after they are separated<br />

source: SW GmbH<br />

This system is used to mill forceps halves made of aluminum.<br />

It has a custom-made automation unit for supplying<br />

material and removing milled parts. It is only intended<br />

for a limited range of parts, but within that range<br />

achieves productivity far beyond any other milling centers<br />

in the plant. With its horizontal, dual-spindle design,<br />

the new machining center delivers two completely milled<br />

48 no. 1, <strong>2020</strong>, March

machining center<br />

forceps halves in just three minutes. Thanks to the automation<br />

system, it can do this around the clock, largely<br />

without supervision. The machine also features impressive<br />

repeat accuracy and thus quality of manufactured parts. In<br />

addition, it significantly surpasses the throug<strong>hp</strong>ut performance<br />

of the other machining centers installed on site.<br />

Development partnership in automation<br />

We chose SW first of all because we were impressed by the<br />

productivity of the double spindle concept. Another aspect<br />

was their impeccable references as well as the rela tive proximity,<br />

which would mean short response and travel times<br />

both during the joint development phase to come and also<br />

for any service calls that might be needed. The initial contacts<br />

in the summer of 2017 led to a partnership-based collaboration<br />

during which the possibilities for automation<br />

BA 321<br />

The BA 321 is the two-spindle version of a series<br />

that is available as a one-, two- or four-spindle<br />

machining center depending on the task. It is<br />

suitable for machining workpieces made of aluminum,<br />

cast iron, titanium or steel.<br />

The heart of the monoblock is the working area with<br />

dimensions of 300 x 500 x 375 mm and the spindles,<br />

which are movable in three-axes. The spindles with<br />

HSK-A63 interface reach speeds up to 17,500 rpm<br />

with an output of 32 kW (4200 rpm, 40 % duty<br />

cycle) and a torque of 72 Nm. The spindle distance is<br />

300 mm. The weight of the system is about 8500 kg,<br />

while the standard installation dimensions are<br />

3.60 x 3.13 x 6.00 m (w x h x d). The series 3 is available<br />

as a single-station machine or with a double<br />

swivel carrier.<br />

The feed of the three-axis unit is provided by sturdy<br />

ball screw drives, with rapid traverse axis reaching<br />

speeds of 65/75/75 m/min (x-, y-, z-direction) and axis<br />

acceleration rates of 10, 10 and 15 m/s 2 respectively<br />

with a maximum feed force of 8000 N. The pick-up<br />

tool changing system has a capacity from 2 x 20 to<br />

max. 2 x 60 tools in the two-spindle variant. Tools up<br />

to Ø 70 mm (160 mm with free adjacent slot) with a<br />

maximum length of 275 mm and a maximum weight<br />

of 7.5 kg can be picked up. The chip-to-chip time is<br />

about 2.5 s. The Sinumerik 840 D sl, Bosch Rexroth<br />

IndraMotion MTX or Fanuc 30i are available as<br />

control unit.<br />

of machining processes was clarified. This was followed by<br />

joint design and development of a special machine based<br />

on the model BA 321.<br />

Special press-drawn sections in three different dimensions<br />

are used as raw material. The forceps halves are<br />

carved out of the sections and are not separated by sawing<br />

until the last work cycle. This neatly sidesteps clamping<br />

problems with the extremely slender and delicate forceps<br />

halves from the outset. The final saw cut is made so that<br />

a minimal amount of burr remains to prevent the pieces<br />

from falling down. Otherwise the very delicate tips of the<br />

forceps could be damaged.<br />

The forceps are removed by special adapters loaded into<br />

the spindles from the tool maga zine. They are used to hold<br />

the forceps parts and break off remaining burrs. Then<br />

they are deposited individually on a transport drawer and<br />

moved by conveyor belt to the removal station, where they<br />

are manually inserted in basket racks for the next work<br />

cycles. “The joint development of automation was very<br />

efficient,thanks to the professiona lism of both teams,”<br />

recalls Frank Pauschert.<br />

Delivery and commissioning<br />

Joint development and project planning as well as setup<br />

and trials up to acceptance lasted until June 2018. The necessary<br />

tools were implemented during this phase and an<br />

initial NC program was created based on customer requirements.<br />

After acceptance was completed, the system was<br />

placed in operation at the operating site in June/July 2018.<br />

Since then there have been tests as well as programming<br />

for a total of 18 product variants. The actual ramp-up<br />

began in November 2018. Production has already been<br />

running in 24/6 operation since March 2019, with the system<br />

sometimes running for up to a week with no human<br />

interaction other than supplying material and removing<br />

finished milled parts.<br />

Satisfied with quality, support and service<br />

Thanks to "life startUp" production monitoring in the first<br />

week after commissioning, the employees became familiar<br />

with operating the machine quickly and were able to work<br />

independently with it. With “life data”, an online service<br />

of SW, the machine is continually connected online<br />

to SW, where essential machine parameters are moni tored<br />

nonstop. If problems come up, action is taken immediately.<br />

Good use has already been made of this service, as the machine<br />

operator was supported by remote diagnostics.<br />

“life help” also turned out to be very helpful: when<br />

problems occasionally came up, it provided quick and very<br />

competent consulting, and if a service employee was needed<br />

at all, he was often on site for less than an hour. Without<br />

this service there is much that would not have worked,<br />

or would have taken much longer. An additional BA 321<br />

has already been ordered.<br />

further information: www.sw-machines.de<br />

no. 1, <strong>2020</strong>, March<br />


machining center<br />

Where craftsmanship and<br />

high-tech go hand in hand<br />

For over a century, Okuma has been developing<br />

grinding machines for the highest quality demands.<br />

Though a lot has changed since the beginning,<br />

some aspects remain the same. Okuma CNC<br />

grinders still achieve their high precision, productivity<br />

and longevity due to a symbiosis of craftsmanship<br />

and state-of-the-art technologies.<br />

Okuma is the only single-source CNC provider in the industry<br />

to develop and produce all hardware components,<br />

the controls and the software for the machine tools inhouse.<br />

The development and production from one single<br />

source leads to a perfect combination of hardware, software<br />

and electronics. Due to their outstanding precision<br />

and high productivity, the grinding machines can be<br />

found in several industries. They are used for a wide range<br />

of materials including soft, high-strength and temperature-resistant<br />

materials as well as sintered alloys, Inconel<br />

or chrome-plated workpieces.<br />

Craftsmanship for highest quality<br />

In addition to the modern technologies that Okuma is<br />

constantly developing and optimising, the machine tool<br />

manufacturer also relies on skilled craftsmanship that<br />

has become rare. In the CNC grinders, for example, handscraped<br />

sliding surfaces are used on the guideways and<br />

mounted components. The manufacturing process of hand<br />

scraping is very time-consuming and requires a high degree<br />

of skill and experience. Nevertheless, it is worth not<br />

neglecting this demanding manufacturing method, as the<br />

resulting sliding surfaces have a degree of durability, precision<br />

and quality that could not be achieved with other<br />

methods. With the exceptionally long service life and<br />

availability of the machines, Okuma ensures that the total<br />

cost of ownership (TCO) remains as low as possible.<br />

Okuma grinders possess<br />

hand-scraped sliding surfaces<br />

that help to achieve extreme<br />

precision and longevity<br />

Hand scraping, as it is used<br />

by Okuma, is extremely<br />

time-consuming and requires<br />

a lot of experience and skill<br />

The Okuma OSP-P300GA<br />

control was specifically<br />

devopled for CNC grinders<br />

and allows for ergonomic<br />

as well as efficient<br />

operations<br />

In-house developed control<br />

facilitates operations<br />

All Okuma CNC grinders are equipped with the in-house<br />

control OSP-P300GA, which was developed specifically for<br />

grinding applications. The control has an intuitive user<br />

interface, and very little user input is required. In addition,<br />

the control is easy to customise and can be modified<br />

and individualised with apps allowing for ergonomic and<br />

productive workflows. An example for this is an app for<br />

determining the optimal dressing parameters, which can<br />

be used to perform dressing simply, quickly and with highest<br />

precision.<br />

All-in-one processing from a single source<br />

In addition to stand-alone standard machines, Okuma offers<br />

complex production cells. This not only means an<br />

automation of the grinding processes. Rather, it covers the<br />

entire machining of a workpiece including turning and<br />

milling operations on Okuma machines. Users benefit from<br />

the consistently high manufacturing quality of Okuma<br />

solutions and only need to be familiar with one type of control.<br />

As a result, the Okuma solutions can be used for a wide<br />

range of applications, and only one operator is needed<br />

to control and monitor the entire manufacturing cell.<br />

Especially in times of a shortage of skilled workers, this<br />

proves to be a considerable advantage.<br />

GrindTec <strong>2020</strong>, hall 2, booth 2012<br />

further information: www.okuma.eu<br />

50 no. 1, <strong>2020</strong>, March

A wide variety of<br />

automation solutions<br />

machining center<br />

The following write-up gives you an exciting<br />

insight into the world of automation. From the entry-level<br />

model to the customized solution, everything<br />

is offered and implemented.<br />

The history of automation began when people at work<br />

started transporting bags and other goods from one place<br />

to another using human chains, rather instead of individually.<br />

One of the best-known forms of automation was<br />

invented by Henry Ford, with the assembly of complete<br />

vehicles on an assembly line in 1913.<br />

STUDER offers its customers a wide range of automation<br />

solutions. Loaders are available in various price ranges.<br />

The more functionality the loader needs to offer, the more<br />

complex the loading model becomes.<br />

STUDER easyLoad as a suitable entry-level model<br />

The entry-level models are characterized by solid craftsmanship.<br />

They primarily provide a low-cost option for<br />

feed ing and removing the desired parts to and from the<br />

grinding machine. For the machine types S33, S31, S22<br />

and S41, a loader solution is offered on the basis of a portal<br />

loader system with V-gripper. The STUDER easyload loading<br />

system is suitable for shaft components up to a part<br />

length of 300 mm and a gripper diameter of 4 to 30 mm<br />

(max. interfering contour - Ø 50 mm); it therefore covers<br />

the majority of the part spectrum produced on these machines.<br />

The parts are supplied via a standardized, adjustable<br />

synchronized conveyor. The enclosure for the base<br />

module, which has been adapted to suit the machine<br />

design, enables safe and clean operation of the system.<br />

flexLoad - the loader from the USA<br />

A strong trend towards automation is also<br />

evident in the USA. In response, UNITED<br />

Grinding North America has developed the<br />

flexLoad loading system. The flexLoad - the<br />

name stands for flexibility - comprises of a<br />

six-axis robot, which can move into the<br />

machine on a seventh axis for workpiece<br />

changeover. The robot is currently available<br />

for the three STUDER models S33, S31 and<br />

S41 in the USA.<br />

Additional functions are<br />

available from the mid-range<br />

In the automation mid-range, where there is still an emphasis<br />

on standardization, STUDER also offers suitable solutions<br />

in collaboration with external suppliers. Additional<br />

functions such as deburring, brushing or re-measuring<br />

ground parts can be offered for automation systems in the<br />

mid-range.<br />

For example Wenger Automation & Engineering AG, in addition<br />

to the WeStack cell, which is responsible for the automation<br />

per se, also offers the WeSpeed cell. As the name<br />

suggests, this automation solution ensures quicker loading<br />

and unloading of parts on STUDER cylindrical grinding<br />

machines. The WeFlex is the flexible all-rounder among<br />

the Wenger automation cells, because<br />

the replaceable gripper bodies enable<br />

changeover from shaft to chuck parts<br />

in a flash.<br />

The sky is the limit<br />

As with cars, there are no upper limits<br />

for automation solutions. STUDER has<br />

implemented many different combinations<br />

of machines and technologies in<br />

the past and will also endeavor to do<br />

so seamlessly in the future. Other additional<br />

functions, such as reading and<br />

marking codes on grinding parts as<br />

well as sorting them, pre- and re-measurement<br />

between grinding cycles and<br />

match grinding, are just a few of the<br />

options that can be offered.<br />

GrindTec <strong>2020</strong>, hall 2, booth 2055<br />

STUDER easyLoad for external and universal cylindrical grinding machines<br />

further information: www.studer.com<br />

no. 1, <strong>2020</strong>, March<br />


machining center<br />

The new EMAG systems:<br />

Complete turnkey solutions<br />

from a single source<br />

The production of comprehensive manufacturing<br />

solutions from a single source is the main<br />

requirement for many mechanical engineering<br />

production planners.<br />

Typically, a general contractor would be responsible for the<br />

development of a complex line of interlinked machines<br />

with a variety of technologies. This provides the manufacturing<br />

company with two major benefits: the overall planning<br />

is easier (of the new factory) and a production partner<br />

that guarantees a perfectly designed, flexible, manufacturing<br />

solution, even for the most complex production<br />

situation. For years, the EMAG Group has been this partner,<br />

as it is one of the few machine builders that covers the<br />

entire process chain from soft to hard machining. Now,<br />

the experts are taking the next step with the creation of<br />

EMAG Systems and combining their project engineering<br />

expertise. The new company is the perfect partner for creating<br />

turnkey solutions, and is responsible for the overall<br />

project - combining the experience and knowledge of the<br />

various EMAG branches when necessary.<br />

For example, e-mobility: here, the requirement for<br />

increased quantities is currently shifting the focus to the<br />

establishment of comprehensive production systems. Ultimately,<br />

this is the only way to be able to produce complex<br />

components such as rotor shafts or differentials in a process-consistent<br />

and cost efficient manner. In the interlinked<br />

systems, for example, soft machining, hardening<br />

and hard machining take place in direct succession and<br />

numerous technologies from turning, drilling and milling<br />

to induction hardening and grinding are used. “When<br />

designing a complex system like this, there are naturally<br />

many questions during the planning phase”, explains<br />

Bern hard Böttigheimer, Managing Director of the new<br />

EMAG Systems. “For example, users must understand the<br />

precise benefits and performance limits of the various tool<br />

processes, opportunities for the component assessed and<br />

a reliable process developed on this basis. To compile all<br />

of this information, the user must have access to a large<br />

amount of internal technological expertise. At EMAG, we<br />

have been working toward this for years - we have a variety<br />

of core processes within the Group, and are also developing<br />

in-house automation technology.”<br />

Over the past couple of<br />

years, EMAG has enjoyed<br />

growing success with<br />

turnkey manufacturing<br />

solutions<br />

Bernhard Böttigheimer,<br />

Managing Director of the<br />

new EMAG Systems:<br />

“The demand for complete<br />

turnkey production systems<br />

is growing. We provide<br />

extensive expertise for<br />

this task”<br />

Combined system expertise<br />

With all of these tools at their disposal, EMAG has been<br />

enjoying growing success in the production of turnkey<br />

manufacturing solutions in recent years. The mechanical<br />

engineering company even underwent an audit by a major<br />

OEM, in which all processes and structures relating to the<br />

development of large production systems were successfully<br />

examined. The specialists regularly provide proof of<br />

their system expertise outside the automotive industry, as<br />

demon strated by various solutions for oil production technology<br />

manufacturers. In the past, experts within the individual<br />

EMAG companies performed the corresponding<br />

pro ject management. Why is EMAG Systems now taking<br />

on this task globally? “We are convinced that this business<br />

area is becoming increasingly important. The demand for<br />

complete production systems is growing because the range<br />

of products and parts is also increasing at many supplier<br />

companies and OEMs. This is putting more demand on<br />

production systems to be more flexible, and project engineering<br />

needs are being outsourced by many companies”,<br />

says Bernhard Böttigheimer. And for these customers,<br />

EMAG Systems provides a central point of contact with experience<br />

in comprehensive turnkey production. These specialists,<br />

based in Salach, Germany, will examine each inquiry<br />

in detail, and then determine which technologies are<br />

needed for the project. With this information they will<br />

form a project team, consisting of engineers from different<br />

EMAG companies - this team will work together to form a<br />

completely customized solution for the project.<br />

Although EMAG Systems may be new, the team is not!<br />

There is a variety of experts from within the company who<br />

have been responsible for similar projects for EMAG in the<br />

past. With this team, customers will benefit from the experience<br />

and in-depth knowledge of all of the Group’s technologies.<br />

Within this new organization, the expertise of the<br />

employees will be combined, and the internal processes<br />

will be simplified. This allows those at EMAG Systems to<br />

focus on providing customers with a comprehensive process,<br />

while the individual EMAG companies focus on their<br />

specific technologies.<br />

52 no. 1, <strong>2020</strong>, March

machining center<br />

Initial success confirming the path<br />

Overall, the EMAG Systems experts see their market opportunities<br />

as very positive. After all, in the automotive industry,<br />

for example, many supplier companies must position<br />

themselves much more broadly and establish independent<br />

production solutions for a larger number of different drive<br />

technologies - from the classic “combustion engine” and<br />

hybrid solutions to completely electric. “In this industry,<br />

the demand for our resource planning expertise is growing<br />

quickly” explains Bernhard Böttigheimer. A second factor<br />

in the success of EMAG Systems is Industry 4.0. After all,<br />

Smart Factories that increase the productivity of a location,<br />

or improve process reliability are impossible without comprehensive,<br />

linked systems. This is where EMAG Systems<br />

and its project engineers play a critical role. A variety of cur-<br />

Turbocharger shaft:<br />

the EMAG Group<br />

controls the entire process<br />

chain from soft to hard machining and<br />

therefore repeatedly acts as a general contractor<br />

EMAG Systems - teamwork creates the perfect line solutions<br />

rent projects shows that this full scope approach is working<br />

in the market, especially in e-mobility. For example,<br />

EMAG is currently developing two production systems for<br />

machining a rotor shaft for European customers. “We are<br />

clearly on the right track”, sums up Bernhard Böttig heimer.<br />

“With EMAG Systems, we intend to bring our longstanding<br />

project engineering expertise to the market in a<br />

selective manner, while continuing to grow over the next<br />

few years and at the same time pressing ahead with the<br />

technological development of production systems. We are<br />

in an ideal position for this.”<br />

GrindTec <strong>2020</strong>, hall 3, booth 3002<br />

further information: www.emag.com<br />

Haas grinding machines:<br />

Next level grinding<br />

With the exhibition appearance at GrindTec<br />

Haas is opening a new chapter in its company<br />

history. Under the motto Next Level Grinding, the<br />

visi tors will get to know new efficient solutions.<br />

On nearly 600 m² a variety of high-tech grinding machines<br />

can be seen in action. In addition, there will be live<br />

presentations, goal-oriented consulting sessions and lots of<br />

new businesses. At this year's GrindTec Haas will present<br />

three highly exciting subject areas to its visitors. Not from<br />

the top down, but in direct dialogue.<br />

Next level innovation<br />

Haas opens up new perspectives in grinding processes.<br />

The Next Level Practice demonstrations on the Multigrind ®<br />

grinding machines are real high-tech solutions and in<br />

total certainly the most spectacular and innovative to see<br />

at GrindTec <strong>2020</strong>.<br />

Next level digital<br />

Multigrind ® Horizon becomes the most important component.<br />

Haas shows how to benefit from digitalization today,<br />

with software solutions that make business more economical,<br />

flexible and successful. Haas builds the bridge between<br />

humans and machines and visualizes how analog and<br />

digi tal can merge.<br />

Next level automation<br />

Haas shows automated manufacturing processes and how<br />

its customers benefit directly from the new flexibility, efficiency<br />

and quality.<br />

Haas always offers its customers individually designed<br />

turnkey solutions. The highly flexible grinding machines<br />

from the Multigrind ® series are turned into high-tech tools<br />

by software solutions. One software innovation at the fair<br />

that is se cond to none also includes: a simulation soft ware<br />

that is not a simulation software in the strict sense.<br />

Multigrind ® Styx shows the real data instead of simulating<br />

them on the basis of triangulation, turning simulation<br />

into visualization. Thanks to ray tracing all grinding processes<br />

can be completely mapped in advance. Instead of reconstructing<br />

surfaces, Multigrind ® Styx displays all shapes,<br />

pixel-precise and without restrictions. It shows the workpiece<br />

data down to the smallest detail. Inequalities and<br />

transitions, even ripples in the workpiece surface, are displayed<br />

and can be corrected before the grinding operation<br />

starts. This saves time, material and nerves.<br />

GrindTec <strong>2020</strong>, hall 2, booth 2002<br />

further information: www.multigrind.com<br />

no. 1, <strong>2020</strong>, March<br />


machining center<br />

Liechti Engineering drives efficiency<br />

in turbine blade<br />

Manufacturing with automated adaptive<br />

milling technology and new minimal-quantity<br />

lubrication process<br />

A historic and global ramp-up in aerospace<br />

component production is underway, and turbine<br />

blade manufacturers are under pressure to keep<br />

pace while maintaining absolutely flawless quality<br />

and highest efficiency. As a GF Machining<br />

Solutions brand and the worldwide leader in fiveaxis<br />

airfoil machining solutions for aerospace and<br />

power generation industry turbine manufacturing,<br />

Switzerland-based Liechti Engineering continues<br />

to push technological boundaries with its<br />

automated adaptive blade Milling technology and<br />

its recently benchmarked minimal quantity lubrication<br />

(MQL) concept.<br />

Automated adaptive blade Milling is just one of the many<br />

areas where Liechti Engineering adds value for manufacturers<br />

of high-value aerospace components: while adaptive<br />

Milling is nothing new, the autonomy that Liechti brings<br />

to the table is a true game changer. With its automated<br />

adaptive blade Milling, the workpiece is measured in the<br />

machine and the TURBOSOFT computer-aided manufacturing<br />

(CAM) software generates and optimizes the<br />

tool path. As a result, the Milling machine automatically<br />

begins to machine the blade - no human interaction required<br />

- at highest productivity and quality.<br />

This premium solution, which is fully integrable with<br />

flexible manufacturing systems (FMS), represents a major<br />

stride forward for blade manufacturers made possible by<br />

Liechti’s established airfoil machining expertise and its<br />

TURBOSOFT CAD/CAM software. The automated adaptive<br />

blade Milling technology innovated by Liechti saves time,<br />

boosts productivity, and takes human error out of the<br />

machining equation - all of which have a significantly positive<br />

impact on efficiency.<br />

MQL processing<br />

At the same time, Liechti’s innovative MQL processing has<br />

been recently benchmarked at Blaser Swisslube, an internationally<br />

active developer and producer of high-quality<br />

metalworking fluids, based in Hasle-Rüegsau, Switzerland.<br />

In collaboration with Blaser Swisslube and Solothurn,<br />

Switzerland-based machining specialist Walter AG, Liechti<br />

proved that its MQL concept optimizes the Milling of<br />

steel turbine blades and takes machining efficiency to a<br />

new level.<br />

MQL takes a small amount of lubricant through the spindle<br />

on the cutting tool - right where it’s needed - so there<br />

is no loss of efficiency. In one portion of the benchmarking<br />

at Blaser Swisslube, MQL proved its added value in the<br />

machining of X20 chrome steel blocks, demon strating<br />

both reduced flank wear and very good surface finishing.<br />

In additional testing carried out at Liechti Engineering in<br />

Langnau, Switzerland, a Liechti Turbomill 1400i was used<br />

to process hard-to-machine X20 chrome steel - a true test<br />

of the MQL process. The conclusion: thanks to MQL processing,<br />

cutting edge wear was reduced and tool life was<br />

extended. In fact, tests showed that polishing with MQL<br />

can reduce tool wear by up to five times compared to standard<br />

metalworking fluid.<br />

All cooling methods have their advantages and disadvantages,<br />

and that’s where MQL offers even more gamechanging<br />

potential: by having both metalworking fluid<br />

and MQL at their disposal, blade manufacturers have<br />

greater flexibility because they have the right process for<br />

any material or challenge that comes their way.<br />

All Liechti machines currently in the field can be retrofitted<br />

with MQL and this success-triggering innovation<br />

can be integrated into new Liechti machines as well.<br />

GrindTec <strong>2020</strong>, hall 2, booth 2026<br />

further information: www.gfms.com<br />

54 no. 1, <strong>2020</strong>, March

components<br />

Metall-Chemie GmbH & Co. KG out with corrosion inhibitor TC ® 85<br />

Lubricant manufacturers count on quality<br />

and sustainability<br />

Customers in the global lubricant industry<br />

are increasingly relying on sustainable additives.<br />

Metall-Chemie GmbH & Co. KG can tell this<br />

from the success of the TC ® 85 inhibitor. The additive<br />

reliably prevents corrosion when used in almost<br />

all water-based lubricating greases, synthetic<br />

and semi-synthetic cooling lubricants and biodegradable<br />

hydraulic fluids. Within a short time,<br />

sales of TC ® 85 by the Hamburg-based lubricant<br />

additive specialist have almost tripled - with an<br />

upwards trend.<br />

TC ® 85 caters to responsible producers<br />

Dr. Piotr Tkaczuk, chemist and Head of Business Development<br />

at Metall-Chemie, attributes this to a change in<br />

demand from industrial customers: “Quality is a matter of<br />

course for our customers. Responsible entrepreneurs are<br />

paying more attention to positive secondary characteristics<br />

such as the environmental impact in their purchasing<br />

activities”.<br />

TC ® 85 is essentially a trifunctional organic carboxylic<br />

acid sold in the form of a dry powder. The corrosion inhibitors<br />

TC ® 50 and TC ® 65 from this product family have<br />

proven their worth in numerous formulations with lubricant<br />

manufacturers; their sales remain roughly stable. The<br />

sales success of TC ® 85 is due to its highly concentrated<br />

active ingredient. The white dry powder contains 85 % active<br />

ingredients in the ready-to-dose mixture. Metall-Chemie<br />

has been able to reduce the moisture content to 15 %<br />

through innovative production management.<br />

Advantages for CO 2<br />

footprint and processing<br />

“The advantages are obvious,” says Dr. Tkaczuk. “Less<br />

goods are moved in logistics. A lower transport volume in<br />

the supply chain improves the CO 2<br />

footprint.” In addition,<br />

the higher concentration of active ingredients saves storage<br />

capacity. Thanks to the highly concentrated material,<br />

buyers in the lubricants industry also have to re-order less<br />

frequently.<br />

This significantly reduces the workload of production<br />

employees. Since TC ® 85 is packaged in handy bags of 20 kg<br />

each, filling the production tank is easier; there is less<br />

weight to move.<br />

“In addition, our corrosion inhibitor TC ® 85 is much<br />

more free-flowing, doesn't clump and is therefore easier to<br />

dose and process. Our customers even reduce their energy<br />

costs,” adds Dr. Tkaczuk.<br />

The corrosion inhibitor TC ® 85, designed by the<br />

Hamburg-based company Metall-Chemie GmbH & Co. KG,<br />

supports lubricant producers in the production of more<br />

environmentally-friendly cooling lubricants, lubricating<br />

greases, metalworking oils and hydraulic fluids<br />

Lubricant manufacturers can score points with their customers<br />

with TC ® 85. The registered trademark of Metall-<br />

Chemie stands for more environmental awareness and sustainability<br />

- and responsible companies are attaching more<br />

and more importance to this.<br />

Metall-Chemie GmbH & Co. KG is a globally operating,<br />

highly specialised company of the Metall-Chemie Group.<br />

Metall-Chemie GmbH & Co. KG sells, develops and produces<br />

lubricant additives for oil-based and water-based<br />

applications. In addition to sales offices in Hamburg and<br />

Shanghai, the company is directly represented by selected<br />

distribution partners in numerous countries. Reliable<br />

delivery and sustainable, high product quality have top<br />

priority.<br />

The product portfolio includes different types of lubricant<br />

additives for oil-based and water-based applications.<br />

In addition to various lubricant additives, purchasers and<br />

developers of the petrochemical industry will find applications<br />

such as corrosion inhibitors, metal deactivators,<br />

extreme pressure (EP)/antiwear (AW) additives or friction<br />

modifiers. All products are subject to constant quality controls<br />

and can be customised and modified as needed.<br />

further information: www.mc-chemie.com<br />

no. 1, <strong>2020</strong>, March<br />


components<br />

More time to generate revenue<br />

Wagstaff fights information losses with Tool<br />

Lifecycle Management from TDM Systems. Having<br />

a clear overview of around 4,000 tools pays off<br />

for the machine and equipment manufacturer in<br />

savings of both time and money.<br />

Wagstaff Inc. plays a key role in the aluminum industry:<br />

The family business, which is based in Spokane, Washington,<br />

develops and manufactures equipment and systems<br />

for producing primary aluminum ingots and billets. The<br />

company was founded in 1946 and, since the 1960's, has<br />

been the market leader in aluminum direct chill casting, a<br />

process in which the aluminum melt is poured into a permanent<br />

metal mold. Since then, the company has grown<br />

steadily and today has subsidiaries all over the world, as<br />

well as over 300 customers in 58 countries. The plant in<br />

Spokane alone has around 133,000 ft 2 (12,500 m 2 ) and covers<br />

all process steps from research and development, production,<br />

machining, installation and testing through<br />

to delivery. Meanwhile, the company’s machinery has<br />

grown to include 30 CNC and 30 non-CNC machines. The<br />

number of tools in use has also risen. The increasing complexity<br />

presented the leading technology provider with<br />

several challenges.<br />

Second-hand information<br />

“At some point, around 2004, we realized how much money<br />

we were spending on lost information,” remembered Jeff<br />

Smutny, Manufacturing Engineering Manager at Wagstaff.<br />

Some of the tool data was in the process documents for<br />

each of the product lines; other data was stored in the<br />

CAM system and yet more data was in Excel sheets. Retaining<br />

an overview of this information and using it to fulfill<br />

orders proved difficult: “This approach was not very efficient<br />

and everyone seemed to have a different idea of how<br />

each tool was supposed to be used,” explained Smutny.<br />

“It was costing us time and money.”<br />

Another problem was communication between individual<br />

employees and departments. For example, information<br />

was not exchanged sufficiently between NC programming<br />

and the shopfloor. There was no central database in which<br />

the master data of the tools was saved. “We were relying<br />

on second-hand data instead of having direct access to the<br />

source of the information,” explained Russ Rasmussen,<br />

Manufacturing Engineering Technician at Wagstaff. This<br />

made crucial processes, such as the simulation of a workpiece,<br />

extremely difficult, since it was unclear whether the<br />

data in use was correct and up-to-date.<br />

The tool data management project gets<br />

the go-ahead<br />

It was a visit by Smutny to the headquarters of Walter AG<br />

in Tübingen, Germany, that initially triggered a significant<br />

change at Wagstaff. There the engineer saw that Walter<br />

was using the Tool Lifecycle Management (TLM) system<br />

from TDM Systems and was impressed by the system’s<br />

scope and capabilities: “It was clear that we needed a tool<br />

management system.”<br />

According to Dan Speidel, Director of Sales at TDM<br />

Systems, Inc., the TLM system ensures that tool data is<br />

available in the right place at the right time. It connects<br />

CAM systems, presetting and crib systems as well as CNC<br />

machine control systems, but can also integrate PPS, ERP<br />

and MES systems on the planning and execution level. “To<br />

do this, the system must be able to integrate data from a<br />

variety of sources - from the manufacturer catalog to the<br />

3D models developed in house - into a central data base,”<br />

Speidel stated.<br />

Thus, Tool Lifecycle Management influences the entire<br />

process, from tool selection through their use in production<br />

planning to tool use on the shopfloor. An important<br />

point to note here is that information gathered at each process<br />

step flows continuously back to the central database.<br />

From there, the data can be used across the entire network.<br />

This system was precisely what Wagstaff required.<br />

On the way to increased efficiency<br />

The first step in reorganizing to include the TDM solution<br />

was to define the tools, no easy task when there are roughly<br />

A pintle bearing for a<br />

navigation lock on the<br />

Columbia River that was<br />

machined on one of<br />

Wagstaff’s 5-axis CNC mills<br />

for a U.S. Army Corps of<br />

Engineers facility<br />

Aluminium billets<br />

(continuous cast profiles),<br />

which are produced in<br />

the factory of a<br />

Wagstaff customer<br />

56 no. 1, <strong>2020</strong>, March

components<br />

4,000 tool assemblies and many, many more tool items.<br />

However, this is one step that was definitely worth it, accor<br />

ding to Speidel. In his experience, many companies are<br />

content to use the generic tool models of the CAM system,<br />

but there is a price to pay for that. It means that, in theory,<br />

when the actual available tools are not recorded in any<br />

database, the programmer needs to leave their desk each<br />

time to ask the tool dispensing team or search for the<br />

tools in question themselves. The result: lost time. If, however,<br />

the programmer uses the actual tool graphics from<br />

the beginning instead of the generic models, then the<br />

guesswork and the associated uncertainty are avoided.<br />

If the available tools and items are recorded and listed,<br />

then, according to Speidel, efficiency and reproducible<br />

accuracy are within easy reach.<br />

At the tool selection stage, several more questions need<br />

to be asked: which tools are best suited for which process<br />

steps? And which combinations are particularly efficient?<br />

Today, Tool Lifecycle Management from TDM helps<br />

Wagstaff to quickly answer questions like this by providing<br />

the programmer with basic information about each of<br />

the tools and their potential applications. The system not<br />

only provides support in selecting the right tool for each<br />

NC operation; it also saves geometric and cutting data for<br />

every tool. It creates 3D tool graphics for NC programming<br />

and simulations, and saves tool lists from the NC programs<br />

for future use. In addition, the system saves cutting data,<br />

machining conditions and best practices so that tool use<br />

can be optimized further in the next project.<br />

Faster and more precise<br />

“These TDM functions not only offer great advantages<br />

when we are fulfilling repeat orders,” Smutny continued,<br />

“but they also help us when we face new challenges.” For<br />

example when dealing with a different product or application<br />

but the same material, the programmer can find out<br />

From aluminum oxide to metal<br />

The light metal aluminum is growing in popularity.<br />

No wonder that Wagstaff is growing and growing.<br />

The systems sold by this company produce<br />

primary aluminum, a term which distinguishes it<br />

from aluminum that has been recycled from scrap. The<br />

starting material is a white powder: aluminum oxide,<br />

which was previously obtained by refining bauxite.<br />

Releasing the metal from its bond with oxygen requires<br />

an enormous amount of electricity for electrolysis. As<br />

aluminum oxide does not melt until it reaches 3700 ° F<br />

(2045° C), it is mixed with cryolite to lower the melting<br />

point to 1740° F (950° C). When the process is complete,<br />

the aluminum melt is cast in order to make ingots or<br />

bars, for example. During direct chill casting, which<br />

Wagstaff specializes in, the fluid material is poured<br />

directly into a permanent mold made of metal - the<br />

ingot mold. Rapid cooling in the mold gives the cast<br />

parts a dense, low-pore structure with a smooth surface.<br />

This provides an ideal starting point for using<br />

aluminum in a wide range of industries.<br />

Machining of a large steel hydraulic cylinder weldment<br />

for one of Wagstaff’s aluminum casting product lines<br />

about the previous performance of the tools and assemblies.<br />

He concluded: “Overall we have saved a lot of time<br />

and increased our precision.”<br />

Tool presetting via the software also helps to increase<br />

precision. For this, TDM is working with leading presetting<br />

manufacturers in order to create a two-way communication<br />

system: during the measuring process, the systems<br />

can access the nominal data of each tool assembly saved in<br />

TDM. The measured actual data is then transferred back to<br />

TDM. In this way, the quality of the data can be continuously<br />

improved. This data exchange with TDM is carried<br />

out via DNC or with tool chips. Information about the required<br />

tools and the NC programs arrives at the relevant<br />

machine at the same time as the current actual data of the<br />

preset tools, as well as graphics, photos and/or notes.<br />

TDM Systems has seen that processing precise tool data<br />

can reduce programming and setup times by around 25 %.<br />

At Wagstaff programming times have also been significant ly<br />

reduced: according to Smutny, the company has grown<br />

considerably since TDM was introduced, but the programming<br />

team is still the same size it was in 2004. “We now<br />

spend more time on preparing jobs that bring in revenue<br />

and less time looking for information,” Smutny stated with<br />

satisfaction. “TDM has expanded our scope hugely.”<br />

“Maintaining an overview of around 4,000 tool assemblies<br />

and their items used to be a serious headache and<br />

cost us many man hours - these can now be used for valueadded<br />

work,” Rasmussen points out another advantage: as<br />

the types of cutting tools, extensions, brackets and clamps,<br />

etc. the company has in its crib are know on record, it has<br />

been possible to reduce the crib inventory and the purchasing<br />

volume of new tools and items. Rasmussen admits<br />

that the new system was not readily accepted by all colleagues<br />

to begin with, and many were hesitant. Today it's<br />

different: “One of our programmers recently said that he<br />

couldn’t imagine doing his job without TDM now. TDM<br />

has become a crucial component for success in our work.“<br />

further information: www.tdmsystems.com<br />

no. 1, <strong>2020</strong>, March<br />


impressum<br />

ISSN 2628-5444<br />

Publisher<br />

Benno Keller<br />

tel: + 49 (0)911 2018-200<br />

fax: + 49 (0)911 2018-100<br />

keller@harnisch.com<br />

Editor-in-chief<br />

Eric Schäfer<br />

tel: +49 (0)911 504 98 82<br />

fax: +49 (0)911 506 38 32<br />

eric.schaefer@harnisch.com<br />

company finder<br />

editorial<br />

ANCA............................................................ 46 Liebherr................................................... 40<br />

BOEHLERIT GmbH & Co. KG................21 LMT Tools................................................... 33<br />

Cecimo.......................................................32 MAPAL....................................................14, 23<br />

Managing Editor<br />

Christiane Ebner<br />

tel: +49 (0)911 2018-260<br />

fax: +49 (0)911 2018-100<br />

ebner@harnisch.com<br />

Editor<br />

Tanja Pinke<br />

tel: +49 (0)911 2018-130<br />

fax: +49 (0)911 2018-100<br />

pinke@harnisch.com<br />

Publishing Company<br />

Dr. Harnisch Publications<br />

Management board<br />

Dr. Claus-Jörg Harnisch<br />

Benno Keller<br />

Eschenstrasse 25<br />

90441 Nuremberg<br />

Germany<br />

tel: +49 (0)911 2018-0<br />

fax: +49 (0)911 2018-100<br />

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www.harnisch.com<br />

www.<strong>hp</strong><strong>tooling</strong>-mag.com<br />

Advertising Germany, Austria, Switzerland<br />

Thomas Mlynarik<br />

tel: +49 (0)911 2018-165<br />

tel: +49 (0)9127 902 346<br />

mobil: +49 (0)151 548 181 81<br />

fax: +49 (0)911 2018-100<br />

mlynarik@harnisch.com<br />

Advertising Europe<br />

Britta Steinberg<br />

tel: +49 (0)2309 574 47 40<br />

mobile: +49 (0)176 478 601 38<br />

fax: +49 (0)911 2018-100<br />

steinberg@harnisch.com<br />

Advertising,<br />

North American editor USA, Canada<br />

Bill Kaprelian<br />

tel: +1 262 729 2629<br />

kaprep@harnisch.com<br />

CemeCon Inc............................................. 33<br />

CERATIZIT Group.....................................10<br />

EMAG............................................................52<br />

EMVA............................................................ 33<br />

Facet Precision Tool................................. 46<br />

FEPA...............................................................31<br />

Fraunhofer IPA.......................................... 36<br />

Fraunhofer IWM........................................32<br />

FRITZ STUDER AG..............................35, 51<br />

GF Machining Solutions......................... 54<br />

GrindTec...................................................... 30<br />

Haas.............................................................. 53<br />

Heller Machine Tools...............................32<br />

Hyperion Materials & Technologies... 34<br />

Kapp Niles............................................... 22<br />

LACH DIAMANT.................................16, 26<br />

Leitz...............................................................21<br />

Meister Abrasives.......................................17<br />

Metall-Chemie GmbH & Co. KG.......... 55<br />

Mikron Tool................................................18<br />

Multigrind.................................................. 53<br />

NUM AG...................................................... 34<br />

Okuma......................................................... 50<br />

PaintExpo................................................... 29<br />

REISHAUER AG........................................... 6<br />

Rollomatic.................................................. 44<br />

Sandvik.....................................................9, 20<br />

Schwäbische Werkzeugmaschinen<br />

GmbH (SW)................................................ 48<br />

TDM Systems............................................. 56<br />

TIGRA........................................................... 24<br />

TYROLIT..................................................... 39<br />

Vollmer................................................... 43<br />

Water Jet Sweden.............................. 42<br />

Advertising China, Hong Kong, Taiwan<br />

Mike Hay<br />

tel: +852 9096 8895<br />

mchhay@ringier.com.hk<br />

Advertising Taiwan<br />

Sydney Lai<br />

tel: +886 (0)4 232 973 18<br />

sydneylai@ringier.com.hk<br />

Number of issues <strong>2020</strong><br />

four issues per year<br />

Printed by<br />

Schleunungdruck GmbH<br />

Eltertstrasse 27<br />

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The articles contained in this magazine,<br />

including the illustrations, are subject to<br />

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the publisher is not permitted and will be<br />

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and distribution are transferred to the publisher.<br />

The publisher accepts no liability with regard to<br />

the facts set out in these articles.<br />

advertising index<br />

Boehlerit GmbH & Co. KG........................................................................................29<br />

CERATIZIT Deutschland GmbH......................................................................................5<br />

FRITZ STUDER AG..........................................................................................................25<br />

KAPP NILES....................................................................................................................19<br />

Krebs & Riedel Schleifscheibenfabrik GmbH & Co. KG............................................11<br />

Lach Diamant..................................................................................outside back cover<br />

Landesmesse Stuttgart...........................................................................................3<br />

PUK.........................................................................................................inside back cover<br />

Reishauer AG.......................................................................................................... cover<br />

ROLLOMATIC.................................................................................................................13<br />

TIGRA..............................................................................................................................17<br />

WiN........................................................................................................ inside front cover<br />

58 no. 1, <strong>2020</strong>, March


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