hp tooling 2020 #1

ISSN 2628-5444 

high precision tooling 

Machine Tools, PCD, PVD, CVD, CBN, Hard Metal 2020 - 1 

Reishauer 213.5x201.5mm HP Tooling.indd 1 17.02.2020 09:50:06 

■ Opportunities for cutting tool manufacturers ■ Powerful tools for electric motor production ■ 

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

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2 No. 1 • February 2020

editorial 

Score with creativity 

The heart of 

metal working 

beats in Stuttgart! 

Eric Schäfer 

editor-in-chief 

The year 2020 will - as is 

already foreseeable - be a 

challenge for the global 

economy and thus also for 

the machine tool and the 

machine tool industry and 

its customers. Growth will be 

modest worldwide, if not declining in many places. But 

difficult times are always an opportunity to reinvent 

oneself and to score points with innovations and 

creative solutions. 

First results of these creative efforts can be seen at 

GrindTec 2020, the World Trade Fair for Grinding Technology. 

Although grinding technology is also closely connected 

with the automotive and mechanical engineering 

industries, the overall market for grinding applications 

is still strong. One can certainly expect trend-setting 

processes and advanced technologies from the exhibitors 

at the trade fair. In this issue we will give you a preview 

of what the manufacturers will present at GrindTec. We 

are particularly looking forward to the world premiere of 

the laser machine from the sharpening specialist Vollmer. 

The further development of additive manufacturing is 

a topic for the future, which we also turn our attention to 

in this issue. We report on the possibilities that additive 

manufacturing offers cutting tool manufacturers. 

It is equally interesting how the limits of additive 

manufacturing are being pushed back by new metal 

powders and components. Furthermore, we inform 

you about new manufacturing solutions in medical 

technology, report on the cost-efficient series production 

of turbochargers and present powerful tools for the 

production of electric motors. 

Don't forget to visit our website 

www.harnisch.com and pick up the news between 

this and our next issue of journal of hp tooling! 

ORDER 

YOUR 

TICKET 

NOW! 

International exhibition 

for metal working 

15.–19.09.2020 

Messe Stuttgart 

Germany 

Eric Schäfer 

editor-in-chief 

amb-expo.de/2020

table of contents 

cover story 

The perfect symbiosis between machine and tooling 

Modern thinking has shown that machine tools and tooling can’t be seen as separate entities 6 

materials & tools 

Pushing forward boundaries of additive manufacturing with new metal powders and components 9 

Powerful tools for electric motor production 10 

Reliable, cost effective serial production of turbochargers 14 

50 years Borazon - CBN grinding wheels 16 

Medical screws: efficiency = saving time while increasing precision and quality 18 

Partner for carbide rods and special solutions 21 

«Solutions in new dimensions» - HOLZ-HANDWERK fair 21 

Dressing tools and digital solutions 22 

TIGRA with interesting innovations at the GrindTec show 2020 24 

LACH DIAMANT looks back on 95 years - third part - Hard turning 26 

processes 

Additive manufacturing: opportunities for cutting tool manufacturers 

by Thomas Götz, Andreas Gebhardt and Dr. Marco Schneider 36 

Efficient processing for the benefit of customers and patients 39 

A thoroughly economic alternative - CBN generating grinding 40 

Fine abrasive waterjet bridges the gap - waterjet cutting 42 

machining center 

Full-line supplier VOLLMER introduces its key trio 43 

The easy route to production autonomy 44 

Growing up in the cutting tool industry 46 

HSC milling: highly productive, high-volume production for surgical instruments 48 

Where craftsmanship and high-tech go hand in hand 50 

Complete turnkey solutions from a single source 52 

Automated adaptive milling technology and new minimal-quantity lubrication process 54 

components 

Lubricant manufacturers count on quality and sustainability 55 

More time to generate revenue 56 

departments 

fairs 29 

companies 31 

impressum & company finder 58 

4 no. 1, 2020, March

Ultimate. Universal. 

Ultra-quick. 

The New Silverline – 

Now even better! 

For more information: 

cutting.tools/en/silverline 

TEAM CUTTING TOOLS 

CERATIZIT is a high-technology engineering 

group specialised in cutting tools and 

hard material solutions. 

Tooling the Future 

www.ceratizit.com

cover story 

The perfect symbiosis between 

machine and tooling 

Modern thinking has shown that machine tools and tooling 

can’t be seen as separate entities 

The Swiss company, Reishauer, 

has shaped industrial history 

since its foundation in 1788 when 

the company was initially set up 

as a smithy to make hand tools. 

In 1863, a “taps-lathe” was build to 

make the first threading taps with a 

radial relieving unit. With the growth 

of the tap market share, the company 

was well-positioned to develop 

its first grinding machine in 1928: a 

thread-grinding machine with a single 

rib vitrified grinding wheel. The 

trig ger to develop this machine was a 

lack of equipment on the market that 

could deliver the necessary accuracy 

for thread gauges. At this time, the 

mar ket had no machine on offer that 

could efficiently grind threading taps. 

Hence, the dissatisfaction with existing 

technology triggered Reishauer 

engineers to develop a new type of 

thread-grinding machine. In 1931, 

the first machine went into production 

that was able to grind from solid 

hardened blanks, including the grinding 

of the relief angle. 

1-Continuous generating gear grinding process 

This thread-grinding machine required 

precision gears for setting the 

pitch of the different threads on taps. 

The precision of the threads was directly 

related to the accuracy of the 

gears within the machine. Again, it 

was the dissatisfaction with the status 

quo of technology that drove the engineers 

to find a better way to manufacture 

high precision gears. This dissatisfaction 

led them to the invention 

of a new idea of gear grinding: 

the continuous generating process 

of grinding gear profiles, a process 

Reishauer has been famous since. This 

process delivered gears that were more 

accurate, cheaper, and faster to manufacture 

than by the previous methods 

of tediously grinding gears tooth gap 

by tooth gap. 

Nevertheless, it took fifteen years 

of intensive development work, and 

in 1945 the first continuous-generating 

gear grinding machines were used 

in-house and sold to third parties. The 

success of the thread and gear-grinding 

machines prompted Reishauer to 

halt tool manufacture and concentrate 

exclusively on building machine 

tools. Moreover, as the cost per 

gear ground diminished with increasing 

efficiency of the generating grinding 

process, automotive gear grinding 

gained more interest. In 2006, 

the company decided to concentrate 

fully on gear-grinding machines when 

the manufacture of thread grinders 

stopped. 

In 1998, a familiar pattern of dissatisfaction 

with the status quo repeated 

itself, but in reverse order. The available 

tools for the gear-grinding machines, 

both grinding wheels and diamond 

dressing tools, could no longer 

match the performance potential 

of the continuous generating machines, 

particularly in terms of accuracy. 

For this reason, Reishauer began 

its production of diamond dressing 

tools and laid the foundation of its 

performance portfolio that included 

machine tools and the required tooling. 

In 2008, a grinding wheel factory 

was founded, shortly followed in 

2012 by a manufacturing site for fixturing. 

These steps ensured the full 

potential of the machine tools to 

deliver consistent quality at low costs 

per gear ground. Furthermore, this put 

Reishauer into a position of being able 

to control all factors that influence 

the quality of the continuous generating 

grinding process. The mindset to 

view tooling and machine tools separately 

no longer corresponded to modern 

thinking. 

2-Inside of gear-grinding machine 

with tooling 

grinding 

wheel 

diamond 

dresser 

workholding 

(2x) 

Grinding Wheels 

As the Greek philosopher Aristotle 

stated: “Every tool achieves perfection 

by serving one, instead of many purposes.” 

The company strictly adheres 

to this advice and limits itself to the 

manufacture of tooling that serves 

only one purpose: to grind high precision 

gears on Reishauer machines. The 

grinding wheels, also called “threaded 


cover story 

wheels” once they have been profiled, play a vital role in 

the generating process. The grinding machine delivers the 

kinematics, i.e., the high precision movements that control 

the cutting path of the grinding wheel. For its part, 

the grinding wheel must transfer these precision movements 

onto the gear to be ground, by grinding this precisely 

to a predetermined dimension, surface finish, and structure, 

and within a short cycle time and without causing 

thermal damage. To meet these requirements, Reishauer 

has built one of the most modern and most automated 

grinding wheel factories in the world in Switzerland. In 

contrast to other wheel makers, Reishauer had the advantage 

of dealing with only a few wheel dimensions and only 

one field of application, which made possible this high degree 

of automation. The extensive use of robotics ensures 

uncompromising homogeneity of the finished products as 

Contrary to conventional one-sided pressing operations, 

Reishauer wheels are made on presses and mold setups 

that allow pressing from top and bottom on a simultaneous 

down and upstroke press. This process ensures that 

the resulting hardness gradient across the full width of the 

wheel is minimal. 

The loading of a kiln cart serves as a concrete example. 

Vitrified grinding wheels are fired for several days 

at a temperature marginally below 1,000° C (1,800° F), 

following a carefully established temperature curve, with 

defined ramp, holding and cooling-down temperature 

gradients. Before firing in the kiln, a robot places each 

grinding wheel at a specific position on the kiln cart (illustration 

5). The robot reads and records the position of each 

wheel, which can be retraced if required in the future. 

3-Machine-readable laser engraving on grinding wheel 

5-Robot loading of a kiln cart 

established grinding processes in customer plants that depend 

on this high degree of homogeneity from lot size to 

lot size. After pressing, each grinding wheel is laser-marked 

as soon as it leaves the pressing mold. This laser mark is a 

machine-readable, indelible “birth certificate” (Illustration 

3). This marking allows total control over each subsequent 

processing step and makes each grinding wheel traceable 

to ensure the tool delivers the consistent performance that 

end-users demand. 

4-Pressing grinding wheels from both sides 

Knowing the position of each wheel during the firing process 

in the kiln, and subsequently measuring the hardness 

(modulus of elasticity) of each wheel, allows working out 

the firing conditions in such a way that all wheels have the 

same resulting hardness. 

The comprehensive process monitoring covers all subsequent 

manufacturing steps, such as hardness testing, turning, 

and speed testing. Over-speeding, i.e., speed testing 

each wheel, ensures the safety of the grinding processes at 

end users. In line with the relevant safety laws, Reishauer 

subjects every wheel to an automated over-speeding test 

with a safety factor of 1.5 times the permissible operating 

speed. Again, given the machine-readable wheel markings, 

each wheel speed test remains traceable. 

Diamond dressing tools in symbiosis with the 

grinding wheel and the machine tool 

Before a grinding wheel can deliver the required accuracy 

and material removal rate, it must be dressed by a highprecision 

rotary diamond dressing tool. The dressing of 

the threaded wheel for continuous generation, grinding 

meets several requirements. Firstly, dressing imparts a perfect 

worm profile and makes the threaded wheel free cutting. 

Secondly, dressing removes any impurities or wear 

no. 1, 2020, March 

7

cover story 

that may have been instigated by the grinding process, 

such as the wheel pores stay open to accommodate grinding 

oil and can remove the chips that have been gener - 

ated during the high material removal rates. Diamond is 

the ideal material for dressing tools, as it is much harder 

than the aluminum oxide of the threaded grinding wheels 

employed in the process. 

Only rotary dressing rolls can match the high requirements 

regarding geometry, service life, and efficiency 

during the dressing process. Illustration 6 shows a multistart, 

reverse-plated diamond dresser. Additionally, this 

dresser features an RFID chip that can communicate with 

the machine. 

frequent part changeover is required. This system reduces 

set-up times and increases productivity, translating into 

economic use of the continuous gear-grinding machine for 

small or large batch production. 

As described for the diamond dressing tools, the fixturing 

also can be fitted with RFID chips, and the resulting 

system “machine tool - fixturing - grinding wheel - dressing 

tool” makes for a grinding process perfectly adapted 

to the highest quality requirement both in accuracy and 

in short cycle times. The RFID option allows the tracking 

of the number of fixturing operations, the monitoring of 

maximum and minimum clamping pressures, and the integration 

of preventive maintenance. Furthermore, for a 

known part, the part data stored in the clamping tool can 

assist the machine tool in moving automatically into the 

correct set-up positions. 

6-Diamond dressing tool with RFID ring 

7-Clamping arbor with integrated RFID-chip 

Radio Frequency Identification (RFID) built into dressing 

tools serves, among other things, to generate and utilize 

usage data. The number of potentially remaining dressing 

cycles is stored in the dressing tool and can be read and accounted 

for by the machine. This offers the end-users an 

overview of the potential remaining dressing life, allowing 

stock management and determining when new tooling 

should be ordered. Furthermore, the RFID chip also 

stores all the geometrical data of the dressing tool, which 

is directly read by the machine. For these reasons, input 

data errors are eradicated. Additionally, the end-users 

can choose from further options such as connections to 

internal and external tooling databases. 

Work Holding 

Precision gear grinding results depend on fixturing of 

equal high precision, which only hydraulic expansion can 

deliver with a repeatability of ≤ 3 micrometers. To maintain 

control over the whole gear-grinding process, Reishauer 

decided to make its own fixturing. The clamping tools 

are tailor-made to specific parts. The hydraulic expansion 

mandrels can be coupled to quick-change bases if a 

Made in Switzerland 

The high degree of in-house manufacturing or vertical integration 

is the foundation of the Reishauer performance 

portfolio. All core components are developed in-house and 

manufactured in Switzerland. In this way, the continuous 

generating process holds its leading-edge as the superior 

hard-finishing method for making gears. 

author: 

Walter Graf, Marketing 

Manager Reishauer AG, Switzerland. 

GrindTec 2020, hall 3, booth 3017 

further information: www.reishauer.com 



Pushing forward boundaries of 

additive manufacturing with new 

metal powders and components 

Sandvik and BEAMIT joined forces at Formnext 

2019 in Frankfurt to showcase the strength of 

the two companies’ combined offering in metal 

powder and additive manufacturing. Together the 

companies have leading capabilities across the 

whole additive manufacturing value chain, from 

metal powders to finished components. 

Earlier in 2019, Sandvik acquired a significant stake in 

BEAMIT - a leading European additive manufacturing 

(AM) service provider. The joint Sandvik-BEAMIT booth 

at Formnext featured several industrial additive customer 

use-cases in a wide range of materials, produced via different 

additive processes - along with Sandvik’s wide range of 

Osprey ® metal powders, now also including nickel-based 

superalloys and titanium. These high-grade powders can 

be used to produce light, but extremely durable components, 

with some incredible internal geometries that maximize 

their performance characteristics, making them suitable 

for use in demanding industries such as aerospace, 

automotive and energy. With these additions to the material 

program, Sandvik now offers one of the widest alloy 

programs on the market for additive manufacturing. In 

addition, the company’s additive machine park includes 

all relevant additive manufacturing processes for metals - 

meaning that Sandvik can tailor the powder to any printing 

process. 

High-profile 3D-printed components 

The Sandvik-BEAMIT booth featured some high-profile 

3D-printed components which underline the tremendous 

pace of technological advancement in the additive manufacturing 

sector. These include the world’s first 3D-printed 

diamond composite. This super-hard material is produced 

using an advanced proprietary Sandvik-process, printing 

in a slurry consisting of diamond powder and polymer, 

using a method called stereolithography, where complex 

parts are produced, layer by layer, using ultraviolet 

light. A tailor-made, post-processing method then makes it 

possible to achieve the exact properties of the super-hard 

diamond composite. 

“Until now, the production of super-hard diamond materials 

has only allowed for a few simple geometric configurations 

to be formed. But the new process means it 

is now possible to 3D-print diamond composites into almost 

any shape, which can revolutionize the way industries 

use the hardest natural material on the planet”, says 

Mikael Schuisky, VP and head of R&D and operations, 

Sandvik Additive Manufacturing. Another innovation on 

display at Formnext 2019 was the world’s first 3D-printed, 

smash-proof guitar (in titanium, of course), tested by rock 

legend Yngwie Malmsteen, and produced earlier this year 

as a means of showcasing the highly precise and amazing 

durable nature of the additive manufacturing process - and 

the strength of titanium. 

Revolutionizing milling cutter in titanium and 

3D-printed parts in super duplex 

Another innovation on display from Sandvik is the 3Dprinted 

lightweight CoroMill ® 390 titanium milling cutter, 

which is produced through additive manufacturing, 

reducing its weight by 80 % and increasing its productivity 

by up to 200 %. Sandvik has also produced 3D-printed 

parts in super duplex steel Osprey ® 2507-AM, with hardness 

and corrosion resistance properties that make them ideal 

for the harsh conditions encountered in the offshore and 

marine industries. 

Yngwie Malmsteen testing the 

3D-print smash-proof titanium guitar 

information: www.additive.sandvik 


9


Creating stator bores in a single operation 

Powerful tools for electric motor production 

The position of the automotive 

industry is clear. Over the 

next ten years practically every 

car maker will be building electric 

cars by the million - with 

clean electric motors and as 

plug- in hybrids. However, the 

question remains: are the right 

tools available for the large-scale 

production of electric motors? 

At EMO 2019, CERATIZIT 

demon strated an extremely effective 

tool programme that provides 

the perfect technical and 

commercial solution for every 

ma chining task encountered in 

the production of electric motors. 

The two newly developed 

fine boring tools for the highperformance 

high volume production 

of electric motor housings 

are simply outstanding. 

Present situation 

The machining demands represented 

by the housing of a car’s electric 

motor are no different from those of 

an internal combustion engine, apart 

from the stator bore of the thin-walled 

electric motor housing. Depending on 

the size and type of the motor, the 

stator bore will vary between approximately 

Ø 200 mm and 300 mm, extend 

to a depth of more than 300 mm 

and must satisfy extremely tight accuracy 

requirements; for example, tolerances 

conforming to IT6 and roundness 

criteria as low as 2/100 mm. 

These are huge challenges for a finishing 

tool designed to produce the 

complete bore in a single operation 

in high volume production. However, 

they have to be met if electric motors 

are to be produced in a timely and 

economic manner in quantities in excess 

of 100,000. 

Solid steel tools are ill-equipped for 

these tasks, as they are far too heavy 

for most machine spindles. The solution 

is to be found in lightweight 

bodies that reduce the tool weight to 

somewhere below 20 kg, which today’s 

standard CNC machining centres are 

able to accommodate. Available in 

multi-step designs for complete machining 

applications, they feature 

several cutting edges per step and in 

some cases guide rails as well. Despite 

their light weight, fine boring tools 

like these must possess a high degree 

of rigidity to successfully transmit the 

power to the cutting edges and hence 

achieve the required tolerance results 

Additively manufactured 

high-end solution 

With its new fine boring tool, which 

is additively manufactured throughout, 

CERATIZIT has developed a special 

tool for stator bores that satisfies 

all the stipulated requirements and 

leaves nothing to be desired in terms 

of machining speed and precision. 

The totally new design makes it rigid 

enough to satisfy IT6 tolerance requirements 

and the corresponding 

roundness criteria. 

Despite its large diameter (in excess 

of 200 mm) and considerable length, 

the developers have managed to keep 

the weight of the fine boring tool below 

17 kg and designed it to accommodate 

the tilting moment of machining 

centres. That such a lightweight 

tool can be manufactured at 

all is down to the experience in 3D 

printing gained over the years by 

CERATIZIT. The delicate, optimally 

braced structure of the base body can 

only be produced by an additive manufacturing 

(AM) process. Experienced 

AM designers, who are not only aware 

of the potential offered by generative 

manufacturing but are also familiar 

with the requirements of 3D printing, 

have used FEM calculations to investigate 

the effective forces and optimise 

Produce stator bores at unbelievable 

levels of efficiency; with the new 

special tool from CERATIZIT 

that will soon be possible 

the topology of the structure. The result 

is a fine boring tool whose design 

can be scaled almost at will to meet a 

customer’s needs. With four cutting 

edges per step and up to five steps per 

tool, even challenging boring tasks 

can be completed at high feed rates in 

a single operation. 

Effective plug & play solution 

The PCD cutting edges are soldered 

into cartridges that are also additively 

manufactured. This eliminates any 

heat input into the base body and 

prevents the associated deformation. 

Once the loaded cartridges have been 

fitted into the designated fixtures in 

the base body, CERATIZIT grinds the 

tool to precisely the required size - 



with micrometre precision. Customers obtain a plug & play 

solution that will enable them to achieve process-secure 

machining results that are always within specification. 

By using 3D printing, CERATIZIT was able to take advantage 

of other strengths of the additive manufacturing process. 

The coolant holes in both the base body and the cartridges 

are designed such that every cutting edge receives 

exactly the amount of coolant it needs while at the same 

time flushing the chips out of the bore. Scratched surfaces 

are avoided, which contributes greatly to increased process 

security and a reduction in waste. 

it’s no less innovative. It is more affordable and of a modular 

design that makes it easier to manufacture. 

Lightweight construction and the AM expertise at 

CERATIZIT were also to the fore in this new development. 

The CERATIZIT branch in Stuttgart-Vaihingen is responsible 

for the individual design of the fine boring tool with 

regard to tool size, guide rails and the required number of 

steps. It is also where the tools are manufactured on an 

ultra-modern machine. 

The advantages at a glance: 

➤ complete finish machining of the stator bore 

in a single operation 

➤ up to five steps, each with four PCD cutting edges, 

offers high-performance capability 

➤ extremely precise machining results 

(tolerance class IT6) 

➤ topology-optimised, additively manufactured 

lightweight body 

➤ additively manufactured tool cartridges with 

soldered PCD cutting edges 

➤ optimised coolant hole configuration for cooling 

each cutting edge and flushing chips out of the bore 

➤ customer-specific design 

Plastic step boring bar for the stator bore 

CERATIZIT has developed another fine boring tool for the 

electric motor housing. Its design is somewhat simpler, but 

Thanks to its incredibly innovative design, the weight of the 

tool is reduced to well below what the market has come to 

expect and is consequently exactly what anyone involved 

in the machining of stator bores in a single operation 

on machining centres has been waiting for 

KREBS & RIEDEL 

Schleifscheibenfabrik GmbH & Co. KG 

• CBN and Diamond Wheels in Vitrified Bond 

• Grinding Wheels in Vitrified Bond 

• Grinding Wheels in Resinoid Bond 

• Fiber-reinforced Cut-off and Rough Grinding Wheels 

Innovative Grinding Technology since 1895! 

Visit us: 

Hall 2 

Stand 2031 

18 - 21 March 2020 

Augsburg 

Grinding Perfection for 

every Process! 

KREBS & RIEDEL 

Schleifscheibenfabrik GmbH & Co. KG 

Bremer Str. 44 • 34385 Bad Karlshafen 

Phone: +49 5672 184-0 

E-Mail: mail@krebs-riedel.de 

Web: www.krebs-riedel.de 

hv02di20


The plastic step boring bar consists of 

a tubular lightweight base body that 

is made using conventional cutting 

pro cesses. The diameters of the stator 

bore are fashioned using additively 

manufactured steps containing cartridges 

equipped with PCD or indexable 

inserts. 

Carbon-fibre reinforced 

special plastic 

These steps are the absolute highlight 

of the tool, as they are created additively 

using a special plastic developed 

by CERATIZIT. The high degree 

of rigidity of the plastic is due to the 

integrated additional materials. Having 

been optimised topologically during 

the development, they are, despite 

their minimal weight, able to divert 

the machining forces generated 

into the base body. The special plastic 

is also vibration-damped, while the 

3D printing method allows the coolant 

holes to be configured as required. 

The coolant can therefore be channelled 

in the best way to flush the 

chips to the rear and out of the hole. 

The cartridges for each step are 

equipped with PCD cutting edges or 

indexable inserts. Not a standard tool 

holder, but a design that prevents 

the tightening torque of the indexable 

insert from acting on the plastic. 

The cartridge also has an electronic 

component that enables fine adjustments 

to be carried out digitally on 

the indexable insert. A display can 

be docked via a digital interface and 

cutter adjustments then performed to 

micrometre-level precision. 

Modular design 

The modular design featuring base 

body and steps allows the light-weight 

counterboring tool to be configured as 

a multi-step tool entirely to a customer’s 

requirements to facili tate the complete 

machining of the stator bore in a 

single operation. Additional enhancements 

to hold an additional tool on 

the front, e.g. for the rotor shaft bearing, 

are under consideration. 

Available quickly 

Customers will love the fact that 

the delivery period is so short, even 

though everything’s made to measure. 

CERATIZIT holds the base body 

as a semi-finished product in stock - 

The new design and forming fixture of the high-end boring tool 

is printed entirely from steel 

with a flexible KOMET ABS or HSK 

interface. The plastic steps are produced 

very quickly on a 3D printer. 

Without having to wait too long, the 

customer therefore receives a tool that 

can be used to machine stator holes 

with previously unattainable levels of 

efficiency. 


➤ flexible machining of stator bore 

to customer’s specification; 

for rough machining, finish 

machining or a combination 

of both 

➤ facility for additional tools 

possible 

➤ extremely precise machining 

results (tolerance class IT6) 

➤ modular tool design 

➤ topology-optimised, additively 

manufactured plastic steps 

➤ digitally adjustable tool cartridges 

can be fitted 

➤ optimised coolant channelling 

for flushing chips out of the bore 

➤ short delivery times 

Tools with intelligence 

CERATIZIT has always made the availa 

bility of digital support for its users a 

priority. KOMET KOMlife, the newly 

developed digital maintenance indicator, 

is a helpful add-on that further 

increases process security. KOMET 

KOMlife can be fitted to the two new 

fine boring tools as well as any rotating 

tool with a diameter of 50 mm 

and above. 

With its KOMlife predictive maintenance 

system, CERATIZIT has set another 

milestone in the development of 

innovative maintenance strategies. 

KOMlife allows operational data to 

be recorded directly on the tool itself 

and displayed on an integrated display, 

which is activated using a magnetic 

stylus. The maintenance indicator 

can be adapted to a customer’s specific 

needs - such as when to change 

a cutting edge - using the adjustable 

maintenance interval. If the interval 

is exceeded, a flashing red LED indicates 

that maintenance is overdue. To 

acquire operational data digitally, the 

recorded data can be retrieved by the 

KOMlife app using the dynamic and 

patented QR code. 


➤ low-cost, digital maintenance 

indicator 

➤ autonomous data acquisition 

on the tool itself 

➤ integrated display 

➤ dynamic QR code - can be read 

using KOMlife app 

➤ for all rotating tools with 

diameters of 50 mm and above 



Ingenious combination of measuring probes 

and spindle head 

Another new CERATIZIT tool is making waves in motor 

machining (and elsewhere): the KOMET MicroKom 

KOMflex spindle head, which is designed for the precise 

machining of bearing seats and cylinder bores, enables 

CERATIZIT to fill the gap between manual spindle tools 

and the flexible U-axis systems. 

The KOMflex is extremely compact and uses the radio 

technology of a measuring probe to intelligently 

produce bores with self-correction (cutting edge compensation). 

This combination of measuring probe and 

spindle head in a single system is unique, offering the 

customer both technological and financial advantages. 

The precision spindle system works completely independently. 

All you need to use for this tool is a machine 

with a built-in radio receiver so that the KOMflex spindle 

head and measuring probe can be controlled. The 

spindle head can also be manually controlled and adjusted 

via the machine control system or a magnetic 

switch located on the head itself. The KOMflex operates 

at speeds of up to 8,000 rpm and ensures positional 

accuracy to 0.001 mm. 

2 O 2 O 

The new boring tool from CERATIZIT has multiple steps 

to enable the entire stator bore to be completely machined 

in a single operation 

Please visit us at Hall 5, Booth 5077 


➤ precise machining of bearing seats and 

cylinder bores 

➤ combination of measuring probe and spindle head 

➤ compact design 

➤ radio technology for intelligent cutter 

compensation 

➤ speeds of up to 8,000 rpm 

➤ adjustable to within 0.001 mm 


information: www.ceratizit.com 

14 - 17 March 2018 

Messe Augsburg 

18 - 21 March 2020 

Messe Augsburg 

www.rollomaticsa.com


Reliable, cost effective serial production 

of turbochargers 

Offer for the complete process 

The turbocharger has been 

state-of-the-art in diesel vehicles 

for some time. And almost all 

automotive manufacturers offer 

a turbocharged petrol engine. 

Why? The turbocharger makes 

comparable performance with a 

smaller engine capacity possible 

and that contributes to the advance 

in downsizing. 

Turbochargers also help to 

achieve lower fuel consumption 

and are therefore fundamental 

in meeting strict emission limits. 

MAPAL offers the complete process 

for machining these parts, 

including tools. 

Challenge for machining tools 

Most turbochargers are exhaust gas 

turbochargers. These look different 

at almost every automotive manufacturer 

and have a special geometry. 

Common to all: there are very high 

temperatures when they are used in 

vehicles with petrol engines. For this 

reason the turbine housing, the socalled 

“hot side” is manufactured 

from very abrasive, heat-resistant materials. 

These materials represent a 

par ticular challenge for every machining 

tool. 

Complex boring tool with 

ISO indexable inserts 

MAPAL has taken up these challenges 

and developed new cutting materials 

and tools. The company offers the 

com plete process for machining turbo 

chargers, including all tools, for example 

drills, milling cutters, reamers 

and mechatronic actuating tools - 

matched to the related geometry of 

the turbocharger. The company also 

assists its customers during the continuous 

further development of processes, 

to reduce cycle times and to 

increase tool lives. As such, combination 

tools that undertake multiple machining 

operations in one machining 

step form part of the portfolio. 

Turning on the machining centre 

using TOOLTRONIC 

A large part of turbocharger machining 

can be implemented using 

tools with ISO indexable inserts. Including 

many machining processes 

on the challenging hot side. MAPAL 

has developed a cutting material specially 

matched to the machining of 

heat- resistant cast steel and that offers 

long tool lives and therefore high 

cost-effec tiveness, despite the abrasiveness 

of the material. 

1. Complex boring tool with 

ISO indexable inserts 

It is necessary to machine the V band 

on every turbocharger. Along with the 

material properties, an interrupted 

cut is often a challenge here during 

pre-machining. MAPAL relies on a 

com plex boring tool with ISO indexable 

inserts to pre-machine the V 

band as well as to pre-machine the internal 

contour of the turbine. The tool 

therefore machines internally and externally 

simultaneously. Multiple steps 

are machined. The tool operates counter-clockwise 

to transport the chips 

out of the component and to prevent 

damage to the internal contour of the 

turbine. 

machining example: 

New face milling cutters 

for roughing 

material: 1.4837 

cooling: MQL 

diameter: 49; 70.5; 73; 90 mm; 

chamfer 10° 

cutting speed: 70 m/min 

feed: 0.4 mm 

tool life: 75 parts 



2. Turning on the machining 

centre using TOOLTRONIC 

A particular challenge during the machining 

of the turbine housing for 

exhaust gas turbochargers is the main 

turbine bore. Its manufacture is subject 

to close tolerances in relation to 

shape, position and surface finish. The 

bore is bell-mouthed shaped to generate 

the best possible flow characteristics. 

MAPAL undertakes this machining 

operation using TOOLTRONIC 

with the LAT attachment (linear actua - 

ting tool). TOOLTRONIC, a mechatronic 

tool system, is a full NC axis 

integrated into the existing machine 

controller. The mounting tool is fitted 

with three inserts, one for roughing 

and two for finishing. 



cooling: MQL 

diameter: 40.5 - 57.295 mm 

cutting speed: 140 m/min (roughing), 

120 m/min (finishing) 

feed: 0.15 - 0.4 mm 


3. New face milling cutters 

for roughing 

MAPAL recently announced a milling 

range with pressed, radial ISO indexable 

inserts. The milling cutter for 

roughing the face surface on the turbocharger 

housing comes from this 

range. The ISO indexable inserts with 

16 usable cutting edges are the highlight 

of this face milling cutter. As 

such the usage of the tool is particularly 

economical. 



cooling: dry machining 

diameter: 125 mm, 14 inserts 


feed: 0.12 mm 


4. Diameter turning tool with 

tangential technology 

The new tool from MAPAL for pre-machining 

the catalytic converter flange 

is also particularly cost-effective. Tangential 

technology is used on this diameter 

turning tool. Due to the upright 

and horizontal installation of 

the LTHU inserts, in effect eight cutting 

edges can be used per indexable insert. 



cooling: MQL 

diameter: 119 mm 


feed: 0.3 mm 


Diameter turning tool with 

tangential technology 

The four tools mentioned demonstrate 

on the one hand the different 

machining tasks on a turbocharger 

and on the other hand symbolise 

the variety of tools and know-how 

available from MAPAL. From standard 

mil ling cutters, through mechatronic 

actuating tools, to complex boring 

tools, the programme includes all 

the tools necessary for machining turbochargers, 

including the tool clamping 

systems. MAPAL designs the complete 

machining process such that the 

most reliable and cost-effective strategy 

for the customer is used. There 

is always a close eye on accuracy 

down to the μm so that the turbochargers 

achieve the highest possible 

efficiency in operation. 

MAPAL offers the complete process for machining turbochargers 

information: www.mapal.com 


15


50 years Borazon - 

CBN grinding wheels 

… and another anniversary 

for pioneer LACH DIAMANT 

In 1969, during the spring tradefair in Hanover, LACH DIAMANT 

was the first manufacturer worldwide to demonstrate the grinding of 

HSS and high-alloy steel on a tool grinding machine. The experts were 

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

chips «produced» during grinding… 

First Borazon/CBN presentation stand 

at the spring tradefair in Hanover in 1969 

( General Electric) 

At the same time, the first CBN grinding 

wheel for dry grinding of an HSS milling 

cutter had its premiere. These were the beginnings 

of LACH DIAMANT’s grinding 

wheels first known as Borazon - a trademark 

of General Electrics, at that time a 

manufacturer of super-abrasives: K-MX for 

resinoid bonds, Bz-Mx for metal bonds. 

«Start with Borazon» - NASA gave 

permission to use the «moon spider», 

visible in the background of the picture, 

for advertising 

Today with a view to the international 

GrindTec tradeshow in Augsburg, from 

March 18th to 21st, 2020, LACH DIAMANT 

offers a proven selection of conventional 

diamond dressing tools, dressing rolls 

and diamond and CBN grinding wheels as 

well as trendsetting 

developments 

which were in recent 

years advertised 

under the 

slogan «Future for 

Today». 

After 50 years of 

Borazon - originally 

advertised as 

the abrasive of a 

new era - the unchallenged culmination of success was 

the metal-bond profile grinding wheel «contour-profiled» 

- a time and cost killer for production grinding of highalloyed 

steel, regarding profiles. 

Revolutionary deep grinding with 

«contour-profiled», metal-bond diamond 

and CBN profile grinding wheels – 

showing a CBN grinding wheel 

(Ø 400 mm) on a mini «contour-profiled» 

spark grinding machine EDG-plus 

To date, LACH DIAMANT has not only solved unimaginable 

grinding tasks, but has also developed a special 

electrical discharge (EDG) profiling machine for regrinding 

even the most precise concave and convex profiles of 

2-4 µ. It is available for service and for resale. 


Featuring the «miracle machine» - the «contour-profiled» 

spark grinding machine EGD-plus by LACH DIAMANT 

information: www.lach-diamant.de 



Meet the experts 

Meet the experts of Meister Abrasives and Alfons Schmeier 

Abrasives showcasing their 2020 high performance grinding wheel 

innovations at GrindTec, Augsburg. The group is known for its best 

product performance following the vision revolutionizing grinding 

technology. Key to sustainable, innovative solutions are 100 % 

customer focus, technical experts and the competent world wide 

distribution network. 

This year’s key technology innovations 

are the world’s first Vitrified Micron 

(VM) for extremely fine surfaces, HPL for 

maxi mum removal rate and hDD 2.0 for 

highest productivity. 

Daily technical forum presentations on this 

year’s innovations will be held at the booth 

at 10:30 h, 13:30 h and 16 h. 

Tools cut better 

with TIGRA 

PCD 

PcBN 

Tungsten Carbide 


VM micro structure 

for extremely fine surfaces 

Customised 

preforms 

PCD and PcBN in 

blanks and segments 

HPL technology for max. removal rate 

Carbide rods 

and milling cutter 

blanks 

Carbide inserts for 

tipping with PCD 

hDD 2.0 technology 

for highest productivity 

information: www.meister-abrasives.com 

We´ll be there! 

Hall 5-5036 

TIGRA GmbH 

Gewerbering 2 

D-86698 Oberndorf am Lech 

Germany 

Tel +49 (0)9090 9680-01 

Fax +49 (0)9090 9680-50 

sales@tigra.de 

www.tigra.com


Efficiency = saving time while increasing 

precision and quality 

Medical screws 

A drill, a milling cutter, an ultimate machining 

strategy with perfectly tuned parameters; this 

is needed, when machining medical screws made 

from titanium or stainless steels. Mikron Tool 

developed a turn-key solution, which simultaneously 

does the machining of hex lobular bone 

screws (better known as Torx ® ) 50 % faster, guaranteeing 

also a high degree of precision of the 

profile and achieving nearly burr-free results. 

With an increasing tendency, yearly 900 million medical 

screws are produced. Each second which can be gained in 

the process counts. Most of these screws are produced on 

lathe machines, on the main spindle the thread and on 

the sub-spindle the hexalobular Torx ® socket is machined. 

That particular operation is usually slower and defines the 

cycle time. Here is an opportunity to improve the efficiency, 

all be it by only a few seconds. Nevertheless it saves 

the manufacturer time and money. 

Mikron Tool offers with the HEXALOBE-Program a turn 

key solution, which is not only based on the cutting tools, 

but also delivers a package with the best machining strategy 

and the right parameters. Because during the development 

of the program it became quite clear that good 

results can only be obtained when all factors fall in place 

correctly. 

Titanium or stainless steels? 

The two materials with which today 90 % of all medical 

screws are made are titanium and stainless steels. These 

are quite different when it comes to their behavior during 

the chip removal process. Such that during the development 

it became clear that the tools as well as the suitable 

strategy needed a differentiation. Especially with titanium 

with its high elasticity stronger cutting force was required, 

which in turn produced higher stress on the cutting edges. 

This already meant right from the beginning of the development, 

that a different carbide was called for. 

For the machining process, both materials have to be 

differentiated. While with titanium the helical interpolation 

and also side milling are possible, Mikron Tool only 

recom mends side milling when working with stainless 

steels. Even though this particular process is a bit more 

time consuming. 

The strategy 

A well-defined strategy was just as important as the cutting 

tools when development was initiated. Because when choo s - 

ing the tools it must be clear how these are being applied. 

Right from the beginning different approaches were considered. 

Especially efficient turned out to be the one which 

could do with a minimum of different tools i.e. stepdrilling 

- milling the hexalobe - subsequent deburring. Other 

strategies like predrilling of the six exterior diameters and 

the center with the following milling and deburring were 

a challenge, especially when working with Titanium. It 

turned out to be a demanding task for the micro drills. 

The milling process, in the chosen strategy the most 

time consuming operation, 

can be done with 

helical interpolation 

(with max. pitch 0.8 x d) 

or with side milling 

(with step over max. 

0.5 x d). Each procedure 

has its pros and cons: 

with helical interpolation 

there will be a 

slight lateral load at the 

milling cutter (Fx), since 

there is also a simultaneous 

vertical stress 

(Fz). 

Screws 

Torx ® socket 

A higher stress on the 

cutting edge corners has 

to be reckoned with and 

because of this they 

were geometrically rein 

forced. Generally this 



Helical interpolation - side milling 

Cutting tools (combined drill and milling cutter) 

produces a faster and more fluid operation. With the side 

milling (or wall milling) the total depth is reached in 

several steps, since only two axes are used for each step. 

The step-over stays the same for the entire operation even 

though the radial stress on the cutter is more elevated. 

Reduce four to two 

The four operations (pre-hole drilling - chamfering - milling 

- deburring) need to be completed in three operations 

with two tools. First a step drill does the center bore and a 

chamfer of 120° and this right away with an excellent surface 

quality of Ra 0.2 um, Rz 0.8 um. After the milling of 

the final shape, this tool will be used once again in the last 

operation to achieve a nearly burr-free surface and superior 

surface quality. The milling cutter with 3 or 4 flutes - depending 

on diameter - is available in two standard lengths, 

so that depending of the screw type, different Torx shapes 

can be machined. It’s high stiffness allows machining 

with high feeds and massive stepover, while still guaranteeing 

the necessary hexalobular profile accuracy. The surface 

quality is given by the special geometry which also affords 

to work with high stepover so that the operation can 

be completed with few steps. 

First experiences with the new CrazyDrill und Crazy- 

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

MORI have shown, that cycle time compared to other 

on the market available tools could be reduced by 50 to 

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

per flute) and high surface quality (Ra = 0.2 um) can be 

reached. A quite promising result! 

PRECISE. POWERFUL. PRODUCTIVE. 

kapp-niles.com 

information: www.mikron.com 

Focus on Quality 

Besides efficient machining, which means short cycle time 

and long tool-life, the development of the new tools concentrated 

also on achieving top quality. Very tight tolerances 

must be kept to guarantee profile accuracy and wall 

squareness of the hexalobular socket, and this from the 

first to the last screw produced. 

Profile accuracy 

Obviously the surface quality and burr condition are also 

an important topic. The head of development, Alberto 

Gotti, confirms that there is no “perfect solution for all 

cases”. 

Even though, this turn-key program with a combination 

of cutting tools, recommendations for the strategy and 

parameters gives the end-user excellent support, he still 

challenged to find “his” balance between most efficient 

machining, high precision and quality. 

GrindTec 2020 

18 - 21 March 

Messe Augsburg | Germany 

Hall 3 | Booth 3001


Round geometry 

Round inserts promote better profiling with 

long overhangs in narrow grooves 10-26 

Cutting tool and tooling system specialist 

Sandvik Coromant is adding round geometry 

(-RM) inserts to its programme of CoroCut ® QD 

parting off and grooving tools. Round geometry 

allows profiling with long overhangs in narrow 

grooves, while further applications include external 

profiling, the generation of recesses and undercuts, 

and the potential to use non-linear turning 

and grooving with a full radial bottom. 

“The features and benefits of using round geometry inserts 

with CoroCut ® QD holders include better tool life and chip 

control with a rigid insert seat, internal over- and undercoolant 

for improved process security and chip evacuation, 

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

Angélica González, Global Product Manager - 

Turning tools at Sandvik Coromant. 

CoroCut ® QD-RM with blade 

A customer case example ably demonstrates the potential 

gains on offer. A shaft made from 42CrMo4 alloy 

steel required grooving operations on a Niles- Simmons 

N30 CNC lathe. Using a CoroCut ® QD holder with -RM 

geo metry inserts in place of a competitor solution saw tool 

life doubled with far better chip control. The cutting data 

was identical for both tools: 

290 rpm spindle speed; 

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

0.3 mm/rev (0.012 in/rev) feed rate; 

and 2.7 mm (0.079 in) axial depth of cut. 

Three grades are available for the inserts. GC1125 grade 

is ideal for finishing in all materials, as well as certain 

roughing operations in non-ferrous metals, heat-resistant 

super alloys (HRSAs) and titanium, while GC1135 grade is 

first choice for roughing in stainless steel and HRSAs. Also 

offered is GC4335 grade for roughing steel and cast-iron 

workpieces. 

The assortment is available in four insert sizes of 

3, 4, 6 and 8 mm (0.008, 0.157, 0.236 and 0.315 inch). 

CoroCut ® QD-RM geometry 

information: www.sandvik.coromant.com 


Partner for carbide rods 

and special solutions 


Boehlerit is a true pioneer in the development 

of cutting materials from carbide and a European 

premium manufacturer whose outstanding expertise 

results from its close links with the steel industry. 

The result: high-end grade solutions for 

ro ta ting carbide tools that are suitable for a wide 

range of applications. 

The Kapfenberg-based tool manufacturer looks back on 

many years' experience with carbide blanks and semi-finished 

products for the precision tool industry and offers a 

multitude of special material grades with varying grain 

sizes. The micro-grain carbide grades HB10F, HB20F and 

HB30F were developed for the machining of non-ferrous 

metals, aluminium alloys, fibre-reinforced plastics, graphite, 

low- and medium-hard casting materials, chilled casting 

and hardened steels. Furthermore, Boehlerit offers two 

special grades in the micro-grain range with HB20UF and 

HB44UF. HB20UF is ideal for the pro cessing of composites 

as well as for HSC milling. HB44UF is used for all rotating 

tools within the field of HSC technology and for the machining 

of hardened steels up to 64 HRC. 

HB40T, a special carbide grade that was developed by 

Boehlerit, offers a combination of toughness and wear resistance 

that is ideal for the roughing of titanium. When it 

comes to mil ling titanium, its toughness poses a challenge 

for the cutting material used, as it leads to high temperatures 

and wear levels on the tool blade. To counteract this, 

tools require a sophisticated combination of metallic hard 

materials that 

have contradictory 

properties. 

Carbide grade 

HB40T offers an 

ideal combination 

of high 

wear resistance 

and toughness. 

Boehlerit offers 

the HB40T 

grade as a bar 

mate rial. These 

blanks are perfect 

for the ma nu facturing of shaft tools that are used for 

titanium roughing applications, for example. The HB40T 

is thus the starting point of choice for tooling applications 

in almost all industrial areas where titanium is processed. 

Typical areas of application include the processing of aeroplane 

structure parts or engine components, products in 

the medi cal technology sector or com po nents for chemical 

or energy plants. 

New in the Boehlerit portfolio is the extremely wearresistant, 

ultra-fine grain grade HB05UF, the ideal solution 

for the processing of abrasive compounds and materials in 

a hardness range of > 64 HRC. 


information: www.boehlerit.com 

«Solutions in new dimensions» 

Leitz will exibit at Holz-Handwerk 2020 in 

Nuremberg, March 18 to 21, 2020. The world market 

leader from Oberkochen will be presenting 

service concepts, industry highlights and innovations 

and supplements to the range for the woodworking 

and wood-processing industries under 

the motto “Solutions in new dimensions”. 

Focus on regrinding - tools as new, 

in manufacturer quality 

One of the focal points will be the Leitz regrinding service. 

Over the past decades, Leitz has managed to establish an 

unrivalled level of customer proximity with its global network 

of highly qualified service stations and set the benchmark 

for perfect service. At the fair, Leitz will present service 

concepts that make it clear that reshapening and reconditioning 

tools in manufacturer quality is the only 

economic alternative to disposable products. Leitz sees itself 

as a partner of the trade, especially for small and medium-sized 

companies, with its logistics and consulting 

concept, which is operated exclusively with its own qualified 

experts from the industry 

and with guaranteed 

short delivery times. 

Leitz will also present its 

digital solutions such as 

the proven Leitz XPress- 

Button or the Leitz XPert 

solution concept. 

Focus on furniture 

production - when diversity meets individuality 

For the furniture industry, Leitz offers a tool solution for 

every conceivable challenge. Whether it be circular sawblades 

such as the RazorCut for perfect panel cutting, the 

Diamaster EdgeExpert shank cutter for perfect nesting or 

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

unrivalled perfect hole edges with the highest boring 

performance. 

HOLZ-HANDWERK 2020, hall 10, booth 206 

information: www.leitz.org 


21


A wide product range 

Dressing tools and digital solutions 

KAPP NILES, as a manufacturer of gear and 

profile grinding machines, offers highly developed 

technologies with various tool concepts adapted 

to the respective task. The product range in 

the tool sector includes dressing tools for dressing 

vitri fied bonded grinding tools and non-dressable 

grinding tools with CBN- and diamond coating. 

Dressing tools can be used for the following processes: 

KAPP NILES offers dressing rolls in galvanic positive and 

nega tive versions for the generating grinding. These are 

used for flexible, workpiece-bonded or topological dressing 

of vitrified bonded corundum grinding worms. 

Diamond profile rolls with or without head dressing device 

For the profile grinding process KAPP NILES offers diamond 

form rolls in sintered design. In addition to the economical 

version with natural diamond, the durable version 

with set CVD diamond plates is also used. The diamond 

form rolls can be reground several times and are 

characterised by a long tool life. 

Diamond dressing gears are available for gear honing. 

These bring the correct tooth geometry quickly and accurately 

into the corresponding honing ring and guarantee 

the quality desired at the component. 

In addition to the dressing tools, CBN and diamond 

grinding tools have been part of the product range for over 

40 years. KAPP NILES manufactures non-dressable, electroplated 

single-layer CBN and diamond tools for finishing 

Multi-groove diamond full profile rolls 

of gears and profiles. The tools are characterised by long 

tool life, accuracy and regrindable bodies and are among 

the top products worldwide. They are used when the highest 

demands are placed on quality, performance and economy. 

The CBN coating can be renewed more than 50 

times, thus contributing to the conservation of resources. 

On request, tools can be equipped with RFID chips, 

which enables integration into a tool data management 

system such as KN assist. 

Provision of set-up and tool data via 

RFID technology 

As well as constant optimisation of machining times, the 

reduction of set-up and non-productive periods also always 

play an important role in a flexible production environment. 

In addition to machine concepts with optimised 

set-up times, KAPP NILES offers intelligent components. 

KN extender 

For set-up processes the technological data of components 

and tools is made available to the controller by using 

RFID technology, which enable an identification without 

any contact between antennas and RFID chips in the 

machine. In order to correctly identify the components, 

the operator is guided through intuitive step by step menu 

navigation, thus reducing the possibility for faulty inputs. 



The key advantages of RFID technology are that it prevents 

incorrect component installation, it automatically 

reads and transfers component data, it prevents incorrect 

entries, which results in shortening of the overall input 

time, as well as preventing downtimes due to incorrect 

component installation. 

Tool data management and digital workbench 

KAPP NILES has developed its own platform called KN assist 

which contains a tool data management system among 

other features. Exchangeable, intelligent components with 

all geometric and process-related data can be managed and 

clearly displayed outside of the machine within the tool 

data management system. All tool data is therefore stored 

centrally in a single location and is retrieved from there. 

KN assist also provides supportive functions for the setup 

process. This means that essential assembly and disassembly 

operations for multi-part-tooling can be carried out 

by the operator in advance. This results in shorter preparation 

times for the subsequent grinding project. Furthermore, 

information is provided to the intelligent components 

which, together with the RFID technology, optimises 

the set-up process. 

CBN grinding worms 

KN assist, together with the KN extender (computer assembly 

for workshops, which equips workbenches with 

digital functionalities), manages the customer’s operation, 

labelling and management of all components outside of 

the machine. Besides the identification of components by 

RFID, optical component recognition is also possible. The 

system is designed to also manage components without 

RFID or a QR code/DMC identification. 


information: www.kapp-niles.com 

With additive manufacturing to more productivity 

If the weight of PCD tools is reduced, as a rule 

significantly higher cutting data can be used. 

Along with design freedom, the possibility of 

weight optimisation is one of the crucial advantages 

offered by 3D printing. Due to the specially 

developed structures inside the tool, which cannot 

be manufactured conventionally, the weight 

can be reduced significantly. 

New bell tool with low weight, 

long tool life and best cutting data 

An example of how MAPAL uses this advantage of 3D 

printing in practice is the new bell tools with brazed PCD 

inserts. Bell tools are used for the external machining of 

hose connections, among other applications. These connections, 

for example on turbochargers, must satisfy com - 

plex contour requirements. Manufacturing must be cor re - 

spondingly precise. Existing processes are also subject to 

continuous improvement so that manufacturing is costeffective 

and reliable in series production. 

MAPAL has therefore optimised the existing, conventionally 

manufactured bell tool. Using the selective laser 

melting process, the inside of the tool has been modified 

- instead of solid material there is now a specially designed 

honeycomb structure. As a consequence, the tool is 

30 % lighter and the tool life is increased by approx. 40 % 

due to the damping effect. It is therefore possible to machine 

faster; the machining quality remains at the same 

high level. 

MAPAL is presenting a new 

bell tool with low weight, 

long tool life and 

best cutting data 

The honeycomb structure 

inside the tool can be 

realised thanks to 

additive manufacturing 

In total the machining time has been reduced by 50 %. 

Furthermore, the cooling channel design has also been optimised. 

The new bell tool is of hybrid design. Using selective 

laser melting, the new tool geometry is printed on a 

highly precise tool body with a HSK-63 connection. The 

additively manufactured part is subsequently machined 

conventionally. Then the PCD inserts are brazed in place 

and cut to shape using a laser. 

information: www.mapal.com 


23


TIGRA with 

interesting innovations 

at the GrindTec show 2020 

For the Oberndorf-based company TIGRA the 

importance of the Augsburg GrindTec is growing 

each year. The world's leading tradeshow for 

grinding technologies takes place every two years 

and has proven itself for many years as an ideal 

platform to inform customers and interested parties 

of the latest developments and innovations for 

the processing of metal, composite materials, aluminium, 

board materials, wood and many more. 

Significant investments in TIGRA's production over the last 

few years have resulted in many innovations, which the 

Bavarian company will present at GrindTec 2020 in Hall 

5-5036. In the spotlight of the impressively grown product 

range for tool tipping are especially carbide blanks, which 

are manufactured in Oberndorf am Lech, as well as ultrahard 

cutting materials such as PCD and PcBN. 

Solid carbide blanks, so-called preforms, are used for 

the production of end mills with central and decentralised 

coolant holes, also with lateral exits at various angles 

and aligned with the chip surfaces. The chip spaces are 

preformed. The design of the blank dimensions is based 

on the customer's blank and finished drawings. The parts 

are subject to multi-stage quality controls and are near to 

finished contour, thus the customer has low grinding and 

erosion effort. Depending on the application, TIGRA offers 

two different carbide grades for this purpose, which have 

TIGRA has various carbide blanks in its program, the preformed 

blanks or so-called preforms are manufactured individually 

according to customer drawings; the milling cutter blanks are 

available from stock in the diameter range from 8 to 25 mm, 

they can have 2-5 radial coolant exits and are h6 ground, 

with or without Weldon surface 

TIGRA supplies PCD blanks and segments with PCD layer 

thicknesses of 0.5, 0.7 and 1 mm, the segments are laser-cut or 

eroded according to customer requirements, for the hard milling 

sector, blanks and segments are available made of PcBN 

optimized soldering and toughness properties for tipping 

with PCD or PcBN. TIGRA's short delivery times are also 

important for the customer. 

Further carbide blanks are flat bars and rods in application-specific 

carbide grades and in various dimensions, 

standard milling cutter blanks with central coolant hole 

and two to five radial coolant exits as well as carbide inserts 

for positive and negative plates for tipping with diamond 

and PcBN. The wide range of saw tips for circular 

and band saws will also be presented to the international 

trade visitors. They are manufactured in metric and inch 

sizes. Unique to TIGRA is the fact that every single saw tip 

is subject to 100 % quality control! Depending on the carbide 

grade, the carbide saw tips are used for sawing steel 

with coolant, for cutting non-ferrous metals, for machining 

cast iron and for heavily interrupted cuts. 

Further information at www.tigra.com or from the new 

TIGRA catalogue for the machining of metal and composite 

materials, which will be published at GrindTec. During 

the tradeshow, TIGRA offers interested visitors the opportunity 

to visit the nearby company by shuttle vehicle and 

to see the production processes with a tour of the company. 

Further information is available on site at the exhibition 

stand or via TIGRA's service sales@tigra.com. 


information: www.tigra.com 


THE ART OF GRINDING. 

BECAUSE PRECISION IS CREATED UNDER A KEEN EYE. 

Fritz Studer AG, established in 1912, is a market and technology 

leader in universal, external and internal cylindrical grinding as 

well as noncircular grinding. Visit us at MACH 2020 on our 

booth 530, hall 7. 

studer.com 

The Art of Grinding. 

A member of the UNITED GRINDING Group


LACH DIAMANT looks back on 98 years - third part - Hard turning 

Poly - poly - or what? 

How grinding times of several hours became turning times 

of a few minutes… 

Horst Lach, managing director 

and CEO of LACH DIAMANT 

agreed to write an ongoing series 

of articles about the development 

of diamond and CBN tools 

and grinding wheels in modern 

industries. 

Horst Lach is known as a true industry 

veteran, and we are excited 

to have this pioneer of techno - 

logy share some insights from 

over 59 years of professional experience 

in the diamond tool 

business. 

In the fifth part of this (almost) 

historical review, Horst Lach 

looks back to the very beginnings 

of hard turning. 

We are in part three of our article 

series “Poly - poly - or what?”, 

looking back at the time between 

autumn 1974 and the Hanover 

Trade Show in the spring of 1975. 

Dealing with this new cutting material 

“polycrystalline diamonds” (PCD) was 

fascinating for all of us; after the presentation 

at the first Hanover Trade 

Show in 1973, each day brought new 

insights for production and for different 

applications. The diamond cutters 

- familiar with the production of 

natural turning diamonds and polished 

turning diamonds for the jewellery 

industry and for the turning of 

copper commutators - were especially 

amazed by the superior cutting abilities 

of this new material in comparison 

with natural diamonds. 

Two examples: Interrupted cuts, almost 

in all cases disastrous for natural 

diamonds. PCD allows for high feed 

rates up to the cutting width (even 

for the now available “large” PCD cutting 

edges), while natural cutting edges 

only allow for a range within µ- or 

up to 1/100 mm for selected materials. 

Despite this fact, or now more than 

ever, development, production and 

application of the first PCD tools was 

successful in the end; it was a team 

effort and based on the professional 

know-how of diamond cutters such as 

Konrad Wagner, a master of natural 

diamond grinding who unfortunately 

died much too early, and Gerhard 

Mai with the assistance of machining 

expert Kurt Hemerka (grinding 

wheel production). 

Polycrystalline diamond materials 

resisted even the most artistic skills 

of natural diamond cutters on traditional 

cast grinding wheels (“poly” 

means “much” and does not have any 

growth to guide the trained eye of a 

diamond cutter). A grinding test on 

a resin-bond grinding wheel, manufactured 

by LACH DIAMANT, proved 

to be so successful that we started 

to look for a stable and precise tool 

grinding machine. We found a machine 

manu factured by Kelch, which 

we co-devel oped especially for PCD 

grinding. After a license transfer, we 

continued to build the “pcd-100/300” 

precision tool grinding machine for 

single-tipped PCD and carbide tools 

(see also “Poly - poly - or what?” part 1 

and 2). 

All this obvious excitement, only 

one and a half years after the first PCD 

introduction in 1973, brings to mind 

another great innovation. “Start with 

Borazon ® ”, the abrasive of a new era, 

had been presented at Hanover Trade 

Show in 1969. Borazon ® CBN grinding 

wheels from LACH DIAMANT 

are so well known among tool grinders 

in the tool manufacturing industry 

- as tool and inside grinding 

wheels with increasing production, as 

peripheral grinding wheel for surface 

and circular grinding - that the name 

“Borazon ® ” is clearly associated with 

LACH DIAMANT. 

First presentation in Hanover in 1975 - hard turning instead of grinding 

“Borazon ® ” was there something 

else? As I remember (see “Poly - poly 

- or what?” first part) I had expected 

a polycrystalline CBN cutting material 

back in the beginning of 1973 - 

a sort of “compact Borazon ® cutting 

edge”. 



Moscow beckons with a new 

cutting material “Elbor” 

As luck would have it, we received an inquiry from Hempel 

company, Düsseldorf, which had good business contacts to 

Moscow, and they asked whether we would be interested 

in a new cutting material named “Elbor” manufactured in 

the USSR, a compact CBN material, compressed through 

high-pressure synthesis. 

Of course, yes! Electrified - that would be an understatement. 

And so it happened that Konrad Wagner and I flew 

to Moscow from East Berlin in 1974, in a Tupolew - first 

class as VIPs, organized by Hempel. 

The impressions and experiences of this short trip right 

before Christmas, to an, at that time, unknown world for 

us would be worth a separate report. We found out that 

we got to Moscow 

at the invitation of 

the Russian Ministry 

of Food & Agriculture. 

This government department 

supervises 

15 high-technology 

institutes/manufacturers 

for synthetic 

diamonds and CBN. 

Polycrystalline Elbor’-CBN blade, 

sintered into a matrix 

At that time, 

we visited the 

“Tomilins ky Factory” 

near Moscow, founded 

in 1959, and according 

to their own 

accounts one of the 

leading manufacturers 

of diamond tools 

in the former Soviet Union, and from the 60’s onwards 

also a manufacturer of diamond and CBN grains. Here we 

should get to know “Elbor”. A “new” cutting material, until 

then unknown in the Western world, designed to make 

machining tools for hard machining. 

dreborid-G-AS during machining of a 

metal powder coated steel part 

our flight back, we had to cancel a visit to the top secret 

“Institute for Super Hard Materials V Bakal” in Kiev/ 

Ukraine. We had an invitation from the ministry, and they 

would have even taken us by helicopter to this research 

facility, with up to 1.000 employees. 

Unexpected help by coincidence 

Back in Hanau, we started our first preparations for the 

Hanover Trade Show in 1975. What should we do with 

“Elbor”? We received unexpected help by coincidence, 

sure enough via Borazon ® : a “customer problem” in regards 

to surface grinding a metal powder coated cylinder. 

The customer thought that grinding times with the CBN 

grinding wheel were too long. “Well, let’s try this compact 

CBN «Elbor».“ 

Thought and done. However, as expected, soldering 

without a carbide holder, as with PCD, was unsuccessful. 

At that time, we did not have the option to solder within a 

vacuum, and so we had to sinter the “Elbor” cutting edge. 

The first attempt of making a turning tool in this way was 

already successful. 

By that time, we were very familiar with Borazon ® CBN 

grinding wheels, made from high-alloy hardened steel 

from 58/62 HRc. Compared to grinding, it should be easy 

to use this CBN composite mixture (unlike diamonds 

stable up to 1.500° C) for the superior turning of these 

steels. In this context, the reference to PCD, the polycrystalline 

diamond of General Electrics. 

However, the CBN composite material named “Elbor” 

consisted of a unit with an 8 mm radius and a thickness of 

approximately 6 mm. There was no carrier or carbide layer, 

which would have provided for a solid soldered joint. We 

found comfort in the thought that we would - as usual 

- find a solution in order to achieve a stable connection 

between “Elbor” and holder. 

A license contract for the raw material “Elbor” was 

signed. Unfortunately, on December 22nd, shortly before 

Enthusiastic responses and amazement during the 

first presentation of dreborid-G-AS 


27


“This will be our trade show highlight - we will demonstrate 

it on a Weiler turning lathe”. And so it happened: 

at Hanover Trade Show in spring the “new” product was 

successfully presented as “dreborid-G-AS” for machining 

of metal powder coated turning parts. For the first time, 

hours of grinding times were reduced to minutes of turning 

times, and the surfaces were just as polished. 

The first step towards better performance and more efficiency 

was done. At first it was only a niche market; mainly 

Metco (today Oerlikon-Metco) and Castolin, among other 

manufacturers for metal powder coatings, considered the 

dreborid-G-AS turning tools almost as a gift. Too many 

customers complained about long grinding times during 

the equalisation of flame-sprayed turning parts with nickel, 

chrome and wolfram carbide alloys, no matter whether 

for repairs or wear protection. Right away, we achieved up 

to 90 % reductions - turning instead of grinding (as mentioned 

in MM Maschinenmarkt, issue #3/1976, April). 

The search for other possible applications 

During the initial phase, Metco and Castolin provided 

all their technicians with LACH DIAMANT developed 

repair kits, containing one dreborid-G-AS turning steel 

and a special development, a dreborid-G-diamond grinding 

wheel. Due to the low hardness of CBN, compared to 

PCD, even inexperienced tool grinders were now able to 

re-grind the cutting edge. 

Encouraged by these first experiences and during our 

search for other possible applications, we were inspired by 

the positive experiences during the use of Borazon ® CBN 

grinding wheels. In fact, both procedures, grinding and 

turning, could handle materials like high-alloyed hardened 

steel with a hardness of 58 and 62 HRc. 

We realized that from now on, there would be a “gap” 

between grinding with CBN and machining with polycrystalline 

CBN cutting materials results, despite of continued 

attempts of machining tool manufacturers to counteract 

this tendency with newly developed types of carbides 

and ceramics. 

The alternative to Elbor 

The readers will likely assume that the first successful attempts 

during hard machining were owed to the imported 

CBN cutting material named “Elbor”, but with the initially 

worried-about disadvantage. A solid carbide basis for soldering 

was missing from the 8 mm Ø CBN compact unit. 

More and more often, we ran into the problem that the 

“precious” Elbor cutting edge would break out of its matrix 

after 30 to 35 % usage. 

There was no other alternative manufacturer of polycrystalline 

CBN cutting edges. Until the end of 1975, when 

our PCD supplier GE surprisingly informed us that we 

could order polycrystalline “BZN-compact” boron nitride 

cutting edges from GE, with a carbide basis for soldering. 

Without any hesitation, we switched to “BZN-compact”. 

Apparently, this polycrystalline material had already 

been developed in the mid 60’s, in order to offer it to GE 

subsidiary Carbology. They were not interested at that time 

and did not want to have anything to do with products 

“superior to carbide”. That is how Louis Kapernaros (at the 

time General Manager at GE – Super Abrasives, Worthington, 

Ohio/USA) described the situation years later when 

we had the punch line in this regard: when we presented 

CBN tools at the Hanover Trade Show in 1975, Carbology 

in Frankfurt had already BZN inserts in their safe for some 

time… 

All told, once again the first step to the introduction of 

a new technology had been taken - let’s simply call it the 

“hour of birth of hard turning”… 

dreborid-G-AS during turning of a 

metal powder coated steel part 

Horst Lach 

further information: www.lach-diamant.de 


fairs 

news & facts 

8 th world’s leading trade fair for 

industrial coating technologies 

Surface finishing is the decisive criterion for the suc - 

cess of products, and thus for a company’s competitive 

edge. 

Consequently, industrial coating technologies make an essential 

contribution to value creation. Companies with inhouse 

painting operations and coating job-shops are faced 

with changing and new requirements as a result, which 

necessitate corresponding process adjustments. PaintExpo 

will present the world’s most comprehensive and futureoriented 

solutions to this end at the Karlsruhe Exhibition 

Centre from April, the 21 th through the 24 th , 2020. The exhibition 

portfolio covers everything from pre-treatment, right 

on to quality control and packaging. 

A wide variety of trends and changes will be shown, 

such as new manufacturing technologies, new and modified 

materials and material combinations, the realignment 

of entire industry sectors, shortened product lifecycles and 

smaller lot quantities, personalisation of products, regulatory 

changes, the digital transformation and other goals 

concerning energy efficiency and climate protection. Industrial 

coating technology is concerned by this as well. 

High levels of complexity necessitate 

comprehensive information 

Although some of the issues are by no means new, the com - 

petitiveness of coating operations will increasingly depend 

on how well and quickly they can respond to these changes. 

As a prerequisite, the coating process has to be adapted or 

optimised. The great complexity of painting and coating 

pro cesses with numerous interlinking work steps makes 

comprehensive information concerning trends, technologies, 

new developments and the suppliers throughout the 

entire process sequence indispensable. PaintExpo will present 

a corresponding cross-technology, cross-industry over - 

view with more comprehensive and up-to-date offerings 

than anywhere else in the world. 

Exhibitors will present future-oriented solutions for meeting 

the increasing demands on quality, flexibility and productivity, 

as well as material, energy and cost-efficiency. 

For example, these include new and further developments 

for classic wet chemical pre-treatment, as well as alternative 

processes. 

further information: www.paintexpo.com 

Quattrotec – 

Intelligent turningdrilling 

applications 

with EasySafe system 

12. - 15. May 2020 

Hall A, Booth A0827 

■ Drilling into solid material with flat drilling 

base (including off-centre drilling), inside 

turning, face cutting and longitudinal turning 

– performed with low vibrations and just a 

single tool 

■ EasySafe System – A notch on the under 

side of the indexable insert ensures that it 

can be fitted into the seat speedily and 

100% correctly 

■ Reduces machining and tool changing times 

■ Optimal cutting grades will be available for 

almost every application 

www.boehlerit.com

news & facts 

fairs 

GrindTec 2020: World’s leading trade fair for 

Grinding technology continues to grow despite 

difficult framework conditions 

The ongoing trade crisis with the USA, the automobile 

market shrinking worldwide for the first 

time and the difficult transformation process to 

E-mobility taking place in this country. 

And yet: The AFAG GrindTec organizers currently have 

663 registrations, a moderate increase in comparison to 

the 629 participating companies in January 2018. The 

occupied area has been enlarged. On an area of 46,500 m 2 

GrindTec will present more exhibits than ever before. The 

number of nations participating has also increased, companies 

from 31 countries (29 in 2018) - present status - will 

present their innovations in Augsburg. The proportion of 

foreign exhibitors totals 44 %. 

Grinding techology positions itself with 

exciting trends 

An encouraging sign is thus set by the international grinding 

technology, which continues to show great interest in 

the German market and further pins its hope at GrindTec. 

Even though “harsher winds are blowing”, because grinding 

technology is closely interwoven with the automobile 

and engineering branch. Trade conflicts as well as sanctions 

from major nations are currently having a negative 

effect on the global economy and as a result also on the 

branch. Added to this are political uncertainties and structural 

changes in the automobile industry. 

Thus in the third quarter of 2019, incoming orders decreased 

in Germany by about a quarter. Foreign trade, 

which is extremely important for an export country like 

Germany, is less affected. Seen globally, experts reckon 

here with a decrease of only 4 % for the year 2020. 

Despite all uncertainties the market is still strong! 

Measured against the product value of machine tools in 

Germany, the machine group of “grinding, honing, lapping 

and polishing machines” makes up more than 13 % 

of all cutting and filing machine tools. In addition to this 

is the turnover through the production of grinding tools 

and abrasives, which in Germany with more than a billion 

Euro is just as high as that of the german “grinding, 

honing, lapping and polishing machines”. A good reason 

for the branch to counter the current economic situation 

with innovations, trend-setting methods and advanced 

technologies, and to present itself at GrindTec at the usual 

high technical and technological level. 

High-tech products on everything to do with the production 

and reprocessing of cutting tools are opening up 

new perspectives for tool grinding. Here the branch has its 

sights set firmly on competitive methods such as additive 

manufacturing, electrochemical polishing methods and 

laser processing of hard materials, whilst at the same time 

offering the 

market 

highly 

functional 

solutions 

for tried 

and tested 

processes. 

What - amongst other things - GrindTec visitors 

can expect: 

➤ additive manufactured grinding discs 

➤ grinding discs with integrated sensor technolog 

➤ additive manufactured flow-optimised cooling 

lubricant nozzles 

➤ hybrid grinding machine concepts that also integrate 

other manufacturing technologies 

➤ direct drives in the grinding machine shafts to improve 

dynamic stiffness and precision as well as improving 

performance, to name just a few examples. 

Digitalisation, networking and automation form the basis 

for companies wanting to be successful on the world market. 

The manufacturers of machines and periphery systems 

as well as process and tool technology also supply 

sanswers at GrindTec to the new demands made of tool 

grinding. Providing added value in production technology 

at different places in the world at the same time is 

only possible with a modern network economy. New business 

models with economic potential will arise. Technologies 

such as augmented reality and virtual reality will help 

both the supplier and the user/customer to simplify the 

daily work routine. Here numerous inspirations will likewise 

be found at GrindTec. 

FDPW - competence centre for 

grinding technology 

The Trade Association of Precision Toolmakers (FDPW), together 

with its international partners, presents itself in the 

conference centre of the Augsburg exhibiton centre. In addition 

to this, the association’s service partners also introduce 

themselves personally and supply information about 

their offers, which could be of great interest to the grinding 

technology companies. The GrindTec Forum with its 

lectures on current themes and the Jakob Preh school from 

Bad Neustadt, which is the only vocational school that 

trains precision toolmakers, can also be found here. Together 

with the GrindTec Campus this combination supplies 

insight into the cutting edge of user related research 

and development - the ideal complement to the comprehensive 

offers of further GrindTec exhibitors. 

further information: www.grindtec.de 


companies 

news & facts 

Launching the SEAM Program 

After years of unwavering commitment to quality 

and safety in the use of abrasives and production 

processes, European abrasive companies are again 

joining forces to implement sustainability measures 

industry-wide, thanks to SEAM. 

environment 

labor 

economy 

FEPA, the Federation of European Producers of Abrasives, representing 

over 80 % of the European producers of abrasive 

products, announced the launch of its new program 

focused on sustainability: SEAM - Sustainable European 

Abrasive Manufacturers. 

With the understanding that the value of a “European 

sustainability system” must involve all players within the 

supply chain, the objective of the program is to support 

and assist abrasive manufacturers on their way towards sustainable 

growth and sustainability improvements, mostly 

in production and distribution. 

The plants of the SEAM members enrolled in the program 

must meet a series of minimum requirements orga- 

nized into the three fundamental pillars of sustainability: 

environment, labor and economy. Each company must 

adopt several evolving targets within the three pillars, 

such as energy management, employee safety and business 

continuity. SEAM members must report annually on their 

progress. 

“Sustainability is not just a trend. It is bigger than that. 

Today it is a call for action to companies to act socially responsible. 

And SEAM is the answer to this call. It demonstrates 

the willingness of the European abrasive producers 

to work on making their production more sustainable, 

more efficient, and take a stronger look at the people who 

work for them and the community they belong to,” stated 

Jan Cord Becker, CEO of 

Hermes Abrasives and president 

of FEPA. 

Large, medium and small 

size abrasive manufacturers, 

suppliers and distributors 

have joined SEAM to set a 

European sustainability 

standard that pulls industry 

upward where it can find 

the right balance between 

environmental efficiency, 

production performance, 

labor safety; all pieces of a 

puzzle that betters the life 

of a community, and are 

values which give a strong 

position to European companies 

in the world. 

further information: 

www.fepa-abrasives.org 


31

news & facts 

companies 

CECIMO elects Hans-Martin 

Schneeberger as the new president 

During its meeting held December 5, 2019 in Brussels, 

the CECIMO General Assembly elected Dr. Hans-Martin 

Schneeberger as president of CECIMO for a period of two 

years. His term will focus on the setting of global standards 

and the uptake of artificial intelligence. 

Succeeding in this role Dr. Roland Feichtl, Dr. Hans- Martin 

Schneeberger has been entrusted with the responsibility 

of leading the European Association that represents more 

than a third of the world machine tool (MT) production. 

Dr. Schneeberger is a Swiss citizen born May 14, 1955. 

He has been serving as chairman of the board of directors 

of Schneeberger Holding AG since 2003. Between 1993 

and 2018 he was CEO of the company and between 1988 

and 1993 managing director and head of marketing and 

sales of Schneeberger AG. From 1985 - 1988 Dr. Schneeberger 

was account and project manager within a European-based 

management consulting firm. Since 2007 he 

has been mem ber on the board of Klingelnberg AG, while 

from 2008 - 2018 served as 

board member of Unitectra 

AG, being chairman of the 

board 2014 - 2018. Previously 

he chaired the board of 

Inspire AG. He was a member 

of the board of Swissmem and 

for many years a delegate to 

CECIMO, the European Machine 

Tool Builders Association 

Hans-Martin Schneeberger 

in Brussels. 

Dr. Schneeberger obtained a PhD from the Krannert 

business school (Purdue University, USA) in 1984 and was 

tenure track assistant professor at the Ross business school 

(University of Michigan, 1984 - 1985). Before he received a 

BSc in mechanical engineering in Switzerland. 

further information: www.cecimo.eu 

New partnership with 

Ellison Technologies in the U.S. 

Heller Machine Tools are changing their business 

model in the North American market. 

For the first time ever, Heller has moved to both direct and 

distribution sales and service - providing their customers 

with a more local interface that can provide sales, engineering 

and customer support via their new distribution 

network and still maintain the existing direct key account 

business. 

Heller Machine Tools L.P. are pleased to announce a new 

distribution partnership with Ellison’s Advanced Technologies 

Business Unit in the U.S.; with specific repre sentation in 

the following states: Alabama, Delaware, Georgia, Illinois, 

Maryland, Mississippi, Nebraska, North Carolina, South 

Carolina, Tennessee and Virginia. 

The Ellison Company was founded by James O. Ellison 

in 1955, the company was based in Southern California to 

distribute machines tools and provide after sales service. 

After continued expansion and organic growth, Ellison 

reached 2012 a half billion USD in sales and became one 

of the most successful machine tool suppliers in the USA. 

2015 the company celebrated its 60 th anniversary. 

Today Ellison Technologies is part of Mitsui & Co., Ltd. 

of Japan, which has allowed the company to increase its 

business foot print, as a provider of advanced machining 

solutions to the North American metal cutting manufacturers 

and their global affiliates. 

further information: www.heller.biz 

1 st International Conference on Programmable Materials 

Imagine the rotor of a wind turbine with a surface 

that, depending on the amount of wind, forms 

small dents or scales upon itself in order to control 

the energy yield and the mechanical stress 

for the entire system. 

The material acts proactively and responds to the external 

conditions in the manner in which it was programmed. 

This is the vision of programmable materials. In order to 

exploit the potential of programmable materials, both the 

internal structure of the material and its inherent material 

properties must be thought of as changeable variables. In 

order to achieve the desired outcome at the correct point 

in time when the product is in use, information processing 

has to take place directly within the material. This is a para - 

digm shift in product development that demands more than 

material competence. Engineering sciences, natural sciences 

and computer science must all work together in a new way. 

This is where the 1 st International Conference on Programmable 

Materials comes in. From April 27 - 29, 2020, experts 

from a wide range of disciplines will meet in Berlin 

to learn from each other and to advance the development, 

production and use of programmable materials. 

further information: www.iwm.fraunhofer.de 


companies 

news & facts 

New president of CemeCon Inc. 

Majorie Steed takes the lead 

from Gary Lake 

Change of leadership in the North American CemeCon 

branch: On August 1 st , Marjorie Steed succeeded Gary 

Lake, leading the business of CemeCon Inc. Her promotion 

is part of a planned transition. 

For 21 years CemeCon Inc. has been supplying North 

American tool manufacturers with premium coatings and 

coating technology. Over the years, the company has repeatedly 

expanded its capacity to meet increasing demand. 

In 2004, the subsidiary of CemeCon AG moved to its current 

headquarters, the IST Center in Big Flats, New York. 

For a long time CemeCon Inc. focused on PVD coatings; 

since September 2014, the company has also been using the 

world-leading diamond technology from CemeCon to coat 

cutting tools. With the latest expansion of the new North 

American headquarters to 3,700 m 2 in 2018, CemeCon 

Inc. increased the capacity of their diamond production 

and made room for the future-oriented 

HiPIMS coating 

technology. 

After 20 years of growth, 

CemeCon Inc. employs more 

than fifty people today. 

Marjorie Steed began her career 

at CemeCon 2006. In 

2015, she was named to the 

Marjorie Steed, new President 

of CemeCon Inc. 

CemeCon Inc. board of directors and became vice president 

of operations. On August 1 st , she replaced Gary Lake 

as President of CemeCon Inc., who led the fortunes of the 

North American subsidiary of CemeCon AG for over twenty 

years. 

further information: www.cemecon.de 

Responding to downturn in metalworking industry 

Europe-wide reorganization measures 

LMT Tools continues to implement its strategic 

measures to improve competitiveness. Three transformation 

projects are driving the change. 

With this step, the company is also reacting to changed 

market conditions in the metalworking industry. In times of 

generally declining demand in the metalworking industry, 

LMT Tools is consistently pursuing its strategy, initiated 

in 2017, to improve competitiveness. The company is 

launching three restructuring programs in the areas of 

sales, pro duct management and production, which will be 

implemen ted by the end of the year. The focus is on increasing 

operational efficiency, which also addresses ex- 

cess capacities in Europe. The existing product portfolio 

remains unaffected by the measures. 

LMT Tools will create an agile, customer-centered organization 

within the sales region EMEA. The company 

strengthens its technical sales organization with local appli 

cation expert teams and creates efficient, highly customer-centered 

structures. 

Additionally LMT Tools advances the development of its 

product portfolio at the high-technology sites in Europe by 

focussing on growth areas. A global product management 

will be implemented. 

further information: www.lmt-tools.com 

Chris Yates elected new 

EMVA President 

The European Machine Vision Association (EMVA) 

announced that Chris Yates is president of the 

EMVA effective from the 1 st January 2020. 

Chris succeeds Jochem Herrmann, who has been president 

since 2015 and now decided to step down for spending 

more time with his family. According to the association 

statutes, Chris's election was agreed by the board of directors 

of the EMVA during a board meeting in Berlin, where 

he was elected unanimously. 

Dr Chris Yates is the director of Advanced Technology 

within the Safety, Sensing, & Connectivity business of 

Rockwell Automation, having 

previously been the CEO and 

founder of Odos Imaging prior 

to the company's acquisition 

by Rockwell Automation 

during 2017. Chris holds a degree 

and Ph.D from Imperial 

College London, and has held 

a number of senior roles in 

early stage companies, con centrating 

on the effective translation 

of novel technology to 

products in the market. 

further information: www.emva.org 

Chris Yates 


33

news & facts 

companies 

Partnership creates large independent global 

producer of cemented carbide tool blanks 

Hyperion Materials & Technologies, a global leader 

in developing hard and super-hard materials for a 

wide range of demanding applications, completed 

January 1 st the acquisition of AFC Hartmetall, a 

premium cemented carbide tool blank manufacturer, 

marking the close of the highly complementary 

agreement announced in September. 

“Bringing AFC into the Hyperion group creates an extensive 

product portfolio and expands our manufacturing 

capabilities, boosting our already robust offering and further 

positioning us as the first choice for toolmakers in 

need of high-precision, high-performance solutions for 

drilling and milling applications,” said Ron Voigt, CEO of 

Hyperion. “AFC has an extremely talented workforce and a 

tremendous reputation for supporting customers. Together, 

we will work toward the shared goal of becoming the 

world’s top independent supplier of cemented carbide tool 

blanks.” 

There will be little change as the companies begin the 

integration process. AFC will maintain its own brand identity 

and continue operations at its Mainleus, Germany, 

headquarters. AFC founder Arno Friedrichs stepped down as 

CEO and joined the Hyperion board of directors, and Ralf 

Greifzu, who has led AFC’s global sales for seven years, is 

now vice president and general manager of AFC. In addition, 

AFC employees will participate in Hyperion’s shared 

employee equity program. 

further information: www.hyperionmt.com 

Swiss CNC technology leader expands to India 

NUM AG has opened a branch in Bangalore. With 

this expansion in Asia, the international com - 

pany with headquarters in Teufen, Switzerland, 

further reinforces its position as a technology 

leader in the field of CNC controls. With the expansion 

to India, NUM increases its local presence 

there as well as its customer-oriented sales and 

service offering. 

“The location in Bangalore will enable us to respond much 

more quickly to customer enquiries and further expand 

our brand in the region. We have been well represented in 

China and Taiwan for many years and would now like to 

further strengthen our position in Asia,” says Rajesh Nath, 

managing director of NUM India. This latest expansion secures 

jobs worldwide, as well as creating new employment 

opportunities in India. 

Rajesh Nath and NUM CEO Peter von Rüti set up the 

branch in the south of Bangalore. “By opening a branch in 

India, we are exploiting our growth potential. At the same 

time the Indian team is expanding our expertise in sales, 

service and after-sales support,” adds von Rüti. NUM believes 

that Bangalore, as a high-tech location, will strongly 

influence the CNC market in the future and thus significantly 

promote the development potential for CNC controls. 

With the new office in Bangalore, NUM is now represented 

internationally at twelve locations. 

further information: www.num.com 


companies 

news & facts 

STUDER increases its market share again in 2019 

After a record year in 2018, Fritz Studer 

AG reported another very successful 

year in 2019. With the third best annual 

turnover in the company's history, 

the cylindrical grinding machine 

manufacturer increased its market 

share again, despite difficult market 

conditions. One reason for its success 

is the high proportion of new customers, 

at almost 40 %. 

Sales & machine portfolio 

At the annual press conference Jens Bleher, 

CEO of Fritz Studer AG, reported 

a successful 2019, even if the economic 

situation has deteriorated significantly. 

“With the third best year in the company's 

history we were able to further increase 

our market shares”, says Sandro 

Bottazzo, the company's CSO. STUDER recorded 

strong growth in North America in particular, where it 

achieved the second best result in the company's 100-year 

history. The company was also able to further increase 

its turnover with internal cylindrical grinding machines. 

“In the Asian region in particular we maintained incoming 

orders for internal cylindrical grinding machines at 

the high level 

of 2018”, continues 

Bottazzo. 

Three machine 

types 

also achieved 

record incoming 

orders: the 

S121, the S141 

and the S151, 

the flagship of 

internal cylindrical 

grinding 

machines. 

The new univer 

sal cy lindri 

cal grinding 

machines - 

the favorit, 

the S33 and 

the S31 - have 

also got off to 

a very successful 

start. “The 

launch of the 

Stephan Stoll (COO), Sandro Bottazzo (CSO), 

Daniel Huber (CTO) und Jens Bleher (CEO) 

new universal machines was both a feat of strength and a 

highlight”, explains Bleher. The company didn't even need 

a year to sell around 100 of the new machines. Customers 

underscore the top quality and precision of the new 

machines. In America a long standing STUDER customer, 

who had purchased a new S31, was delighted that he could 

achieve another increase in reliability and precision. 

Our goal is to make our customers 

even more successful 

The customer segments developed very differently in 

2019. In the automotive sector in particular, market conditions 

were much more challenging than in 2018. However, 

thanks to this broad diversification Fritz Studer AG 

was able to offset weaker market segments with stronger 

ones. For example, the aviation industry was one of the 

segments that flourished in 2019. “Our company has also 

been very well positioned in the aerospace customer segment 

for many years and is a preferred supplier of many 

component suppliers”, explains Bottazzo, when reviewing 

the past year. STUDER sees one key to its success in 

its global customer-focused sales and service organization. 

This is also one of the reasons why the proportion of new 

customers was almost 40 % last year. Smaller markets, like 

Great Britain, also achieved a very good order intake in 

2019. Finally, the market share was also increased in the 

company's home market of Switzerland. 


further information: www.studer.com 


35

processes 

Additive manufacturing: 

Opportunities for cutting tool manufacturers 

written by: Thomas Götz, Andreas Gebhardt and Dr. Marco Schneider, 

authors from the Fraunhofer Institute for Manufacturing Engineering and Automation IPA 

Currently, small and medium sized enterprises 

(SMEs) within the German cutting tool industry 

encounter a wide range of challenges. Customer 

requirements in terms of productivity, quality 

consistency and tool life are constantly rising. 

In addition, the sector is undergoing a profound 

change driven by digitization and a fundamental 

transformation of the automotive industry due to 

powertrain hybridization and electrification. From 

a market perspective, the industry is increasingly 

exposed to competition with low-cost cutting 

tools mainly from Asian countries. 

Hence, for German cutting tool manufacturers and particularly 

SMEs reduction of manufacturing costs as well 

as access to new technologies and manufacturing processes 

are keys for maintaining their technological leadership 

position on the world market in the medium to long 

term. The issue of suitable technologies and innovative solutions 

for the future production of cutting tools was addressed 

within the framework of the “Innovationsforum 

Zerspanwerkzeuge” at last year’s International Exhibition 

for Metal Working (AMB). The forum was organized by the 

Fraunhofer Institute for Manufacturing Engineering and Automation 

IPA in Stuttgart funded by the Federal Ministry of 

Education and Research (BMBF). 

The manufacturing chain of the 

cutting tool industry 

Today, cutting tools are predominantly made of composite 

materials, preferably hard metals based on tungsten carbide. 

Here, powder metallurgy is today’s state of the art 

process via high temperature pressing and sintering [1,2,3] . 

The sequence of operations typically involved in a powder 

metallurgy process is depicted schematically in figure 1. 

The process utilizes metal powder that is mixed with a 

binder into a feedstock [4] which is then compacted into 

green parts through a molding and pressing process and 

sintered to bond the particles together [5] . This manufacturing 

process allows for the production of simple geometries 

as well as near net shape geometries such as indexable inserts 

[2] . For more complex geometries as is the case with 

milling tools for example, further machining operations 

need to be applied with geometrically undefined cutting 

edges by means of high hardness abrasive grinding [1,2,6] . 

This process is time and cost consuming and limits the design 

freedom of the inner and outer cutting tool structures 

significantly [1,2] . While macro-geometric features like chip 

flute geometry are limited by both the shape and kinetics 

of the grinding tool, the integration of internal tool structures 

such as internal coolant channels is impossible or 

requires considerable efforts [2] . 

During the last decade, suitable Additive Manufacturing 

technologies (AM) have emerged, however, that provide 

the opportunity to manufacture individual components 

with a high degree of design freedom. These technologies 

like Selective Laser Sintering (SLS) are based on 

powder bed fusion and use a laser to selectively solidify 

the powder. Figure 2 shows the manufacturing process. SLS 

gains the geometric information out of a 3D CAD model 

that is sliced into layers of a certain layer thickness [7] . The 

parts are then produced in a cyclic process. In a first step, 

powder is applied in layers to a retractable platform inside 

a building chamber. Subsequently, cross sections of the 

component to be manufactured are scanned and locally 

fused by the energy input of a laser beam and solidified. 

In the last step of the cycle, the building platform is lowered 

by one layer thickness before a roll applies new powder 

on top of the previous layer. The sequence of powder 

figure 1 

Steps of the powder metallurgy process [Fraunhofer IPA] 


processes 

figure 2 

Schematic of the selective laser sintering process, according to [4] 

application, exposure and lowering of the platform is repeated 

until the three-dimensional object has been built 

up layer by layer [8,9] . 

Additive manufacturing as enabler 

for lightweight construction and 

functional integration 

Especially Selective Laser Sintering as one of different Additive 

Manufacturing technologies is gaining ground as an 

alternative to conventional manufacturing because it offers, 

among other benefits, shape complexity, weight optimization 

and functional integration for near net-shape 

products. Moreover, AM offers a great potential to achieve 

time- and cost-efficiency and to further reduce the need 

for post-processing [2,8] . 

Further potential for cutting tool manufacturers 

arises from the generative design of hollow 

structures and the possibility of functional 

integration. Thus, the static and dynamic behavior 

[2] of cutting tools can be optimized 

through targeted mass and stiffness distributions, 

as can be seen from the example of the 

laser-sintered external reamer by MAPAL, illustrated 

in figure 3. A ribbed structure inside 

the tool enables weight optimization of over 

50 %, which leads to a significant increase in 

productivity with the associated increase in 

cutting speed. The internal cavities also ensure 

an almost perfect concentricity of the 

rotary tool due to the optimized mass distribution, 

so that machining can be carried out 

with higher accuracy [13] . 

The geometric freedom to design internal 

structures such as freeform “drilling” holes 

also permits the integration of new cooling 

concepts. The indexable insert drill constructed 

additively by MAPAL uses a cooling concept 

with spiral cooling channels whose AMgenerated 

triangular shape deviates from the 

conventional circular shape thus offering considerable advantages. 

As compared to a central coolant duct, the use of 

such a cross-section allows the surface moment of inertia 

and the coolant flow rate to be significantly optimized. In 

addition, the specific cooling channel profiles, which run 

parallel to the chip flute, increase the core stability [14] . 

An example of how geometric variability can improve 

cutting tool functionalities is the polycrystalline diamond 

(PCD) screw-in milling cutter developed by the Komet 

Group. Its additively manufactured body, equipped with 

PCD blades, is screwed onto a tool holder. The additive 

procedure permits a modified arrangement of the cutters 

as well as larger axis angles whereby more PCD blades can 

be placed on the cutting tool leading to significant productivity 

gains [10] . As far as flute geometries are concerned, 

AM also permits greater freedom with regard to external 

contours. The Komet Group has developed a PCD-drilling 

tool which, thanks to generatively manufactured filigree 

chip spoilers, prevents chip deposition both in the workpiece 

and the chip flute [11] . While the chip space of conventional 

boring tools is open to the side and to the front, 

the chip spoiler on each cutter covers the flute frontally 

and radially. This leaves a gap of only a few millimeters 

between the chip spoiler and the tool cutting edge, 

through which the resulting chip flows off and is safely 

guided out of the bore via the spoiler channel [11,12] . 

figure 3 

The AM-generated rib structure inside the 

external reamer enables a significant weight reduction 

[MAPAL Dr. Kress KG] 

Economic potential and technological challenges 

in AM for cutting tool manufacturing 

The use of additive processes in the manufacture of cutting 

tools is economically feasible due to their ability to 

produce highly individualized components, especially 

for prototype construction, special tools and small batch 

sizes. Hybrid strategies that combine additive and metalcutting 

manufacturing processes can be used to increase 

economic efficiency even with higher quantities: Simple 


37

processes 

areas such as the basic tool body are manufactured conventionally, 

while more complex areas with integrated 

functions are built up additively [14,15] . 

Desiderates for future applications of additive processes 

in cutting tool manufacturing lie particularly in the field 

of material development. In addition to ceramics, some 

metallic materials such as tungsten carbide can already 

be processed as additives for limited areas of application, 

for example in mold making and for tools used in forming 

technology [16,17] . However, the existing additive processes 

in the field of solid carbide tools are still proving to be unsuitable, 

since cutting edges that are able to withstand the 

high mechanical requirements cannot currently be produced 

in sufficient quality using additive processes [2,17] . 

Conclusion 

The term Additive Manufacturing represents different 

technologies that build components layer by layer via 

digital information using diverse materials such as metals 

or plastics. Since AM requires no individual tools or fixtures, 

it is particularly suited for rapid prototyping, special 

tools and small lot sizes. From an economical and technological 

perspective, crucial advantages are an increased 

design freedom, including the ability to exploit topology 

optimization for lightweight applications. Moreover, AM 

has the ability to incorporate added functionality such as 

internal cooling channels and provides highly complex geo 

metries like hollow structures beyond the limits of conventional 

manufacturing. Reducing the lifecycle time between 

concept, design and actual manufacture makes the additive 

processes economically feasible. To exploit the innovative 

potential of AM beyond existing solutions, further 

research needs to be undertaken with regard to upstream 

and downstream processing steps and the enhancement of 

varied application scenarios. From today’s view, AM is an 

interesting technology with regard to the tool body – for 

application in the field of “cutting edges”, further technological 

developments must be realized. 

Literature 

[1] Friemuth, T. (2002): 

Herstellung spanender Werkzeuge. Postdoctoral thesis. 

in: Fortschrittberichte VDI: Reihe 2, Betriebstechnik 615 (2002) 

[2] Reuber, M.; Schwanekamp, T. (2016): 

Additive Herstellung von Zerspanwerkzeugen aus 

WC-Co-Hartmetall. Potentiale und Herausforderungen. 

in: Industrie 4.0 Management, 2016, 32(5), 12–16 

[3] Sossou, G.; Demoly, F.; Montavon, G.; Gomes, S. (2018): 

An additive manufacturing oriented design approach 

to mechanical assemblies 

in: Journal of Computational Design and Engineering 

5 (2018) 3-18. Accessible: 

https://doi.org/10.1016/j.jcde.2017.11.005 

[4] Kerns, J. (2016): 

Powder-Metallurgy Processes 

accessible: https:// 

www.machinedesign.com/metals/powder-metallurgy-processes 

[5] Kumar, P.; Xavior, A. (2018): 

Processing of Graphene/CNT-Metal Powder 

accessible: http://dx.doi.org/10.5772/intechopen.76897 

[6] Riedel, R.; Chen, I.-W. (2008): 

Ceramics Science and Technology 

volume 1: Structures, WILEY-VCH Verlag 

[7] Poprawe, R. (2011): 

Tailored Light 2. Laser Application Technology. 

in: Springer Verlag 

[8] Klahn, C.; Leutenecker, B.; Meboldt, M. (2014): 

Design for Additive Manufacturing – Supporting the 

Substitution of Components in Series Products 

in: Procedia CIRP 21 (2014) 138-143 

[9] Reiff, C.; Wulle, F.; Riedel, O.; Epple, S.; Onuseit, V. (2018): 

On Inline Process Control For Selective Laser Sintering 

in: 8th International Conference on Mass Customization and 

Personalization – Community of Europe, 19-21 

[10] KOMET-GROUP (2017): 

Additive Herstellverfahren erzeugen 

leistungsfähigere Fräser und Bohrer 

accessible: https://mav.industrie.de/fertigung/werkzeuge/ 

aus-ideen-wachsen-werkzeuge/ 

[11] Gillhuber, A. (2017): 

Filigraner Spänespoiler verhindert 

Spanablagerungen im Bauteil 

accessible: https://www.maschinenmarkt.vogel.de/filigranerspaenespoiler-verhindert-spanablagerungen-im-bauteil-a-576145/ 

[12] KOMET-GROUP (2017): 

Bohrwerkzeug mit Spänespoiler 

accessible: https://www.kometgroup.com/presse/produktedienstleistungen/detail/bohrwerkzeug-mit-spaenespoiler/ 

[13] Leichtbau BW GmbH (2016): 

Leichte Außenreibahlen sorgen für Produktivitätszuwachs – 

Neue Designmöglichkeiten durch selektives Laserschmelzen 

halbieren Gewicht des Werkzeugs der MAPAL Dr. Kress KG 

accessible: https://www.leichtbau-bw.de/fileadmin/_migrated/ 

news_uploads/PM_ThinKing_Januar_Mapal.pdf 

[14] Doris (2015): 

Mapal setzt auf additive Fertigung für 

Schneidplattenbohrer der QTD-Serie 

accessible: https://3druck.com/pressemeldungen/mapal-setzt-aufadditive-fertigung-fuer-schneidplattenbohrer-der-qtd-serie-3636310/ 

[15] Kress, J. (2017): 

Wir zögern nicht, neue Technologien einzuführen 

accessible: https://industrieanzeiger.industrie.de/technik/fertigung/ 

wir-zoegern-nicht-neue-technologien-einzufuehren/ 

[16] Fraunhofer IKTS (2018): 

Extrem hartes Hartmetall aus dem 3D-Drucker 

accessible: https://additive.industrie.de/news/extrem-harteshartmetall-aus-dem-3d-drucker/ 

[17] Reuber, M.; Schwanekamp, T. (2018): 

Vollhartmetallwerkzeuge additiv herstellen 

in: Technische Rundschau, 2018, 68–70 

further information: www.ipa.fraunhofer.de 


processes 

Medical technology 

Efficient processing for the benefit of 

customers and patients 

TYROLIT presented the latest updates 

in medi cal technology grinding applications 

at COMPAMED 2019 in Düsseldorf, Germany. 

The leading manufacturer is focusing among 

other things on core technologies for knee joint 

grinding. 

The trend of an ever-aging society has increasingly 

brought medical advancements and medical technology 

into the spotlight. At the same time, the demand for “spare 

parts” and implants for the human body is increasing in 

order to maintain the quality of life into old age. 

Due to the requirements for precision and small tolerances 

in this industry, manufacturers look to their reliable 

and experienced partners. Continuous innovations for 

over 100 years has enabled TYROLIT to keep its finger on 

the pulse of time. 

Their new lightweight core made of natural fibres 

allows for a significant weight reduction in knee joint 

grinding. The N-LW (natural lightweight) core is not 

only lighter and more cost-effective, but also offers positive 

damping characteristics. 

In grinding femur components 

the use of superabrasive grinding 

tools is the industry standard 

and TYROLIT manufactures 

a double-layered disc 

with a high wheel rim that can 

be used for processing over the 

full 20 mm. 

TYROLIT offers a selection of grinding and polishing 

sleeves for the machining of hip joints. At COMPAMED 

they presented their range of various resin and vitrified 

bonded grinding tools. The productivity of the manufacturing 

process can be increased by using conventional or 

superabrasive grinding tools adapted to the respective application. 

For example, the cycle times for pre-grinding 

could be reduced from 10 to 1 minute. 

A third pillar of their medical technology portfolio is 

the processing of surgical instruments. An updated range 

of grinding and polishing tools from TYROLIT is used for 

a variety of finishing processes. For more safety during 

surgical procedures, scalpels are 

sharpened with TYROLIT COOL 

CUT discs and finished with elastic 

tools, thus guaranteeing the highest 

surface quality. 

further information: www.tyrolit.group/de/ 


39

processes 

CBN generating grinding 

A thoroughly economic alternative 

The demand for high quality gear teeth in 

areas such as electric mobility, for example, 

come with great challenges. Liebherr is working 

on the development of solutions for economic 

manufacturing. 

For many applications, generating grinding with corundum 

is a good solution, but this abrasive also has certain 

disadvantages for some applications. Grinding special geometrical 

modifications could, for example, have a negative 

effect: The modifications would then have to be integrated 

in the tool completely or partially via the dressing process 

in the machine. On one hand, however, profiling a grinding 

worm needs time and, on the other, it alters the geometry 

of the tool. Depending on the choice of grinding 

process, it has to be repeated in very short intervals in 

order to guarantee the production at the same level of 

quality. This is just where Liebherr comes in, offering a 

CBN tool with an implemented modification and demonstrating 

on an example workpiece that extremely economic 

production is possible with these tools. 

CBN stands for cubic boron nitride. Next to diamond, 

it is the second hardest cutting material in the world. It 

consists of a three-dimensional matrix made of boron and 

nitrogen atoms that can develop a broader spectrum of 

crystal forms than diamond. It has high thermal conductivity 

and a low coefficient of friction. In this way, the 

workpiece heats up much less than grinding with corundum, 

for example. It is possible to machine very hard materials 

reliably with CBN. CBN grinding worms can also 

be smaller, which means that the range of applications is 

greater than with corundum. 

to the limited shift possibility, which in turn raises tool 

costs and also cycle times. It may be possible on corundum 

tools (e.g. for distortion-free generating grinding) to 

increase the workpiece number for each dressing interval 

through new mathematical solutions but this also applies 

in the same way to the use of CBN tools. 

With CBN, the dressing times can be dispensed with 

completely, which means that cycle times and thereby 

manufacturing costs can be reduced. CBN is highly 

machinable and generates an extremely low measuring 

complexity. A CBN grinding worm is clamped in and 

the grinding process begins straightaway - with no need 

at all to make corrections beforehand. The unit costs of a 

test workpiece (m = 1.53 mm, z = 81 mm) included a special 

width modification with corundum at 4.25 Euros with 

a cycle time of 114.6 seconds, while the same grinding process 

with CBN was 3.38 Euros cheaper and considerably 

faster with a cycle time of 78 seconds. Where the number 

of producible workpieces per dressing cycle with corundum 

is in the two figure range, it can occasionally reach 

well into the four figure range with a CBN coating. “Each 

situation needs to be assessed individually to determine 

which grinding worm is the most viable. We are happy 

to advise our customers on whether CBN is the better 

alternative for their numbers and application scenarios”, 

offers Andreas Mehr. 

A robust process 

In a dressing-free CBN process, all parameters are predefined 

and “frozen”. This is a crucial difference between 

corundum and CBN processes: All corundum processes 

are subject to changes through dressing, which can impair 

CBN stands for short cycle times and 

long tool life 

CBN tools are currently experiencing a comeback. They 

may be expensive to procure but make gains with the 

unit costs on modifications. Dr. Andreas Mehr, the leading 

grinding technology expert at Liebherr-Verzahntechnik 

GmbH with a PhD in engineering, explains the differences 

of the grinding materials: “We have been using galvanically 

coated CBN since 1988. It is a highly durable 

grinding material. A significant increase in the grinding 

performance of modern corundum has been achieved in 

recent years but, compared with CBN, it comes with the 

disadvantage of the amount of effort required for dressing, 

which is encountered most prominently on topological 

grinding processes.” With these processes, the number of 

workpieces per dressing cycle is significantly reduced due 

CBN generating grinding - a thoroughly economic alternative 


processes 

the grinding worm quality. Examples are wear of the dressing 

tool or diminishing worm diameter: As the worm diameter 

diminishes, the length of the active worm spirals 

are shorter, which reduces the number of active abrasive 

grains. A consequence of this is an increase in the roughness 

factor on the tooth flank, which should remain constant 

throughout the worm tool life. “There is a limit to 

which this can be counteracted through finer dressing processes,” 

explains Andreas Mehr. 

Additional processes, such as dressing, present fault sources 

that simply cannot occur with CBN. CBN processes 

are extremely robust and quality assured, which makes 

them particularly interesting for the economic production 

of high quality gear teeth, such as in the area of electric 

mobility. “Attempts are being made to reduce noise, particularly 

on the very sophisticated electric gears in the 

automotive sector, by changing the macro and micro geometry,” 

explains the expert. 

Liebherr manufactures CBN tools at the Ettlingen factory. 

“Our aims in production are high performance and 

top quality in a very sturdy process”, explains Haider 

Arroum, regional Sales Manager for gear cutting tools. 

The production of CBN grinding worms and discs is 

ütherefore carried out in a closed loop process in which 

measurement results flow immediately back into the production 

para meters as corrections. “We have to carry over 

the configu ration accuracy to manufacture as close to 1:1 

as possible”, says Haider Arroum in substantiating the 

complicated procedure. 


LGG 180 with integrated centrifuge 

LGG 180 with integrated centrifuge 

In most cases, the new generation of electric cars is built in new factories where the focus is on reliable and 

clean processes. At EMO 2019, therefore, Liebherr exhibited a generating gear grinding machine that meets the 

requirements of a clean factory in full: The LGG 180 with integrated centrifuge. The centrifuge station for the 

removal of burrs and coolants is located at the pocket of the ring loader pointing towards the operator side. It 

is mounted decoupled from the machine so that oscillations or vibrations from the centrifugation process do 

not have any effect on the gear quality. Spinning during the machining process is therefore possible. There is 

no loss of oil, the media remain in the machine and the cleaned components can be transported further in any 

automation system. 

Advantages of integrated centrifuge unit: 

t clean factory thanks to integrated centrifuge: dry workpieces, no oil loss, reliable production 

t decoupled centrifuge unit with no transfer of vibrations to grinding machine 

t can be connected to any conventional automation solution 

Advantages of CBN tools: 

t tool mounting, pre-profiling and dressing are dispensed with 

t no adjustment of profile angle necessary 

t easy operation 

t significantly reduced measuring and testing effort 

further information: www.liebherr.com 


41

processes 

Cutting narrow incisions with ultra-high precision 

in high density materials 

Fine abrasive waterjet bridges the gap 

Waterjet cutting is a common method for 

processing parts in high density materials such as 

aluminum, stainless steel, titanium and carbon 

composites. The FAWJ cutting process bridges 

the gap between micro laser and EDM cutting and 

brings water jet cutting into the field of micro 

part processing. 

To enable such levels of precision you need two things: 

- a cutting head and cutting process for FAWJ cutting, 

and 

- a machine built for extreme accuracy. 

The NCM 10 Micro from Water Jet Sweden fulfils both of 

those requirements. 

FAWJ cutting process for 0.2 mm incisions 

The first micro waterjet cutting head was developed by 

Water Jet Sweden in 2008. It is a high precision cutting 

tool producing one of the most precise abrasive water jets 

in the world. The unique cutting head enables an abrasive 

jet diameter down to 0.2 mm. The FAWJ cutting process 

requires very fine abrasives of 230-240 mesh and a special 

CNC controlled dosage abrasive feeder. 

Machine table designed for ± 0.008 accuracy 

To reach the levels of accuracy required in micro part manu - 

facturing, the NCM 10 water jet has a number of unique 

design features to create a rigid table that withstands temperature 

fluctuations: 

Mineral Casting Bearlit table frame - a table frame made 

of a composite material with exceptional stiffness that 

withstands vibrations and temperature fluctuations. 

The frame is integrated in the machine construction 

and motion system as a complete unit. 

Rubber suspended stainless steel water catcher - the 

free-standing catcher solution prevents vibrations and 

temperature variations from influencing the cutting 

process. Stainless steel makes it maintenance free. 

Renishaw Invar Scale in X and Y - with a Renishaw 

Absolute Linear Encoder fitted in both X and Y axes 

you have a micrometer scale with an extremely low 

expansion coefficient and ultra-high resolution. 

Prepared for any kind of fixtures 

The palettized cutting table makes it easy to install fixtures 

and presses for different types of machining. Maximum 

table size is 1x1 m which covers most cutting applications. 

The cutting table is fixed into the table frame to 

enable ultra-high precision cutting. 

“There are many suppliers who state that they offer 

micro cutting machines, but not many can offer a true 

micro part cutting tool with 0.2 mm incision combined 

with ± 0.008 accuracy,” says Tony Rydh, co-founder and 

CTO at Water Jet Sweden. 

Fine abrasive waterjet cutting vs. EDM 

Extruder tool matrix 

tempered tool steel, 

15 mm 

max. speed 

min. speed 

cutting accuracy 

manufacturing time 

prime cost 

NCM 10 

11 mm/min 

4 mm/min 

0.02 mm 

1.30 hours 

180 Euro 

EDM 

1 - 2 mm/min 

about 0.001 mm 

> 8 hours 

480 Euro 

Micro part 

Fine abrasive waterjet - laser 

further information: www.waterjetsweden.com 



Full-line supplier VOLLMER 

introduces its key trio 

All good things come in threes; and the 

trade fair appearance of sharpening specialist 

VOLLMER at GrindTec 2020 will emphasise this 

by presenting itself in Augsburg for the first time 

as a full-line supplier. 

The three consecutive L’s of the term “full-line supplier” 

symbolise the three technologies of grinding, eroding and 

laser machining with which the machine manufacturer 

can completely cover the machining of rotary tools, circular 

saws and band saws. The three L’s also resemble the 111 

years during which the traditional Swabian company has 

been successful on the international market of sharpening 

technology since 1909. With laser technology, VOLLMER 

is becoming a full-line supplier 

As a leading technology and service company, VOLLMER 

develops sharpening machines and automation options for 

precisely machining cutting tools made from carbide and 

tipped with PCD (polycrystalline diamond). VOLLMER's 

latest innovation is the exciting new VLaser 270 laser machine. 

The machine will be introduced to visitors for the 

first time 2020, March 18th to 21st, and will be one of the 

full-line supplier's trade fair highlights. Using the power 

of the laser light and linear drive technology, PCD-tipped 

tools can be precisely machined with the VLaser 270. 

Around a dozen grinding and 

erosion machines on view 

VOLLMER will be bringing around a dozen sharpening 

machines and automation solutions to GrindTec that 

relate to eroding and grinding technology. The VPulse 500 

and QXD 250 wire erosion and disc erosion machines 

will be on show, just like the VHybrid 360 combined 

grinding and erosion machine. Tool manufacturers can 

use the VHybrid 360 to both grind and erode carbide and 

PCD tools such as drills, milling cutters or reamers in a 

single set-up. Three models from the VGrind family will be 

on show in Augsburg: The VGrind 360E basic model, the 

VGrind 360 and the VGrind 340S with linear drive for machining 

extremely small carbide tools. With two new optional 

features, the VGrind 360 optimises productivity for 

tool manufacturers. Due to a higher processing speed, the 

material removal rate can be significantly increased whist 

the simultaneous re place ment of grinding wheels and 

tools significantly reduces non-productive time. 

Machines for machining carbide-tipped circular saw 

blades are traditionally well- represented at the VOLLMER 

GrindTec stand. On the global grinding technology market, 

the VOLLMER machines abbreviated as CHX, CHP, 

CHF and CHD are some of the industry’s best-selling 

technology. Whether in production or resharpening - the 

completely automated and CNC-controlled sharpening 

machines can be found wherever wood, metal, aluminium 

or plastic have to be cut to a precise size with circular saws. 

Service package and digital services 

At GrindTec VOLLMER will also be providing information 

regarding its service package for training, finance, maintenance 

and repair. With the digital initiative V@dison, the 

full-line supplier brings together applications for Industry 

4.0 and IoT (Internet of Things) to connect people and machines. 

The “Visual Support” app provides an innovative 

new access path, which offers VOLLMER customers the 

opportunity to connect directly with the VOLLMER help 

desk. Installed on a smartphone or tablet, the app supports 

the machine operator online, allowing them to take 

and exchange live pictures of a machine using the video 

function. VOLLMER will also be explaining how end users 

can connect various machines with each other via the 

IoT “umati” platform. The umati platform is based upon 

the OPC UA protocol that was developed by the German 

Machine Tool Builder's Association (VDW), together with 

around 50 machine manufacturers. 

GrindTec 2020, hall 1, booth 1006 and 1027 

At GrindTec 2020, VOLLMER will be presenting itself for the first 

time as a full-line supplier for machining tools, circular saws and 

band saws, and will be showcasing machines that use the three 

sharpening technologies grinding, eroding and laser machining 

further information: www.vollmer-group.com 


43


The easy route to 

production autonomy 

More efficient grinding processes thanks to connected solutions 

Autonomous, resource-saving, zero-defect production 

- who doesn't want that? Many companies 

are pushing concepts to achieve this goal, but at 

GrindTec 2020 Rollomatic SA will be showcasing 

realistic solutions designed especially for tool 

grinding. The focus here is on a smart-factory infrastructure, 

new, high-precision grinding and laser 

machines and a comprehensive training program 

covering all aspects of tool grinding. 

The smart factory, autonomous production, the Internet of 

Things: technologies that once appeared to belong in the 

realm of the visionary are now finding their way into production 

halls. And some of them are arriving on the scene 

more quickly than you realize, as inventive developers set 

about turning the fruits of their innovations into marketready 

products. “We have systematically devoted ourselves 

to this field for many years, which means that we now 

enjoy that all-important technological edge. We are extremely 

proud to showcase this at GrindTec 2020, where 

visitors will have the opportunity to experience fully automated 

tool production up close and witness the grippers of 

our NEXTAGE robots in action,” said Damien Wunderlin, 

head of Sales at Rollomatic SA in Le Landeron, Switzerland. 

The smart factory demonstrates the perfect production 

environment of the future; at GrindTec 2020, Rollomatic will 

showcase a range of highly viable solutions that can be deployed 

without problems by almost any tool manufacturer 

Rollomatic offers solutions, not just concepts 

Continuous data analysis, status monitoring, automated 

and monitored processes, cooperation with industrial 

robots - these are the challenges that the factory of the 

future will face. But thanks to Smart Connectivity Solutions 

from Rollomatic, these challenges can be much more easily 

addressed in the field of tool manufacturing. 

Thanks to linear motors 

and hydrostatic technology, 

the GrindSmart® 830XW 

has optimized production 

processes in many factories; 

users benefit from perfect 

surface and cutting edge 

qualities 

At GrindTec 2020, Rollomatic will provide an impressive 

demonstration and showcase of the solutions it has developed 

to tackle these future challenges. “We will be de monstrating 

the standard production process in a tool making 

plant. The ShapeSmart ® NP50 cylindrical grinding 

machine and GrindSmart ® 630XW3 grind the blanks and 

the complete tools. They are then measured and packaged 

ready for dispatch, and the necessary labels are affixed 

to the packaging - just like in regular production, except 

that the work is performed in cooperation with two of our 

NEXTAGE robots,” says Damien Wunderlin. 

A new machine harmony 

In addition to the robots working hand in hand, the two 

grinding machines also “understand” each other: the 

ShapeSmart ® NP50 - the latest addition to the cylindrical 

grinding tool series - promises even greater flexibility, faster 

configuration and improved surface qualities. It covers 

a wide range of diameters from 0.025 mm to 25.0 mm, 

which opens up unlimited possibilities even for more unusual 

length-to-diameter ratios. And the patented Smart 

Punch process opens up myriad possibilities when it comes 

to cylindrical grinding: the ShapeSmart ® NP50 can even 

process complex shapes and out-of-round punches with 

no problems. 

This production duo is complemented by the new six-axis 

tool grinding machine GrindSmart ® 630XW3. Thanks to 

its expanded, ultra-compact grinding wheel changer for 16 

wheels (including coolant distributors), it is ideally adapted 

for unattended operation. This simplifies process management 

and significantly reduces non-productive times. Linear 

motors and a torque motor on the rotating axis ensure 

improved surface qualities and reduce maintenance costs. 



Laser machining with added value - the LaserSmart 510 is not 

only extremely fast, but also offers the option to sharpen 

carbide endmills with CVD coating 

Dream surface qualities! 

When it was unveiled, it caused a sensation: The completely 

redeveloped six-axis GrindSmart ® 830XW was the 

first tool grinding machine to combine the benefits of 

linear motors on x-, y- and z-axes with hydrostatics. The 

product was impressive not only on paper but also in practice, 

as proven by the positive feedback from users who 

deployed this exceptional tool and cutter grinder in production. 

Damien Wunderlin: “Our goal was to further 

reduce friction within the machine and ensure near-zero 

wear. We have eliminated residual friction by combining 

this with a hydrostatic system and effectively dampened 

vibrations. And, judging by the feedback from our customers, 

it seems that our approach has worked. The concept 

offers longer lifetime of the grinding wheels, produce 

perfect surfaces and cutting edges and, above all, ensure 

highly stable production processes - a key USP in the highquality 

segment.” 

A longer life thanks to a sharp CVD edge 

The one virtue of diamonds that machinists love but that 

can cause headaches for tool manufacturers is their hardness. 

While the geometry variants in PCD-equipped or 

CVD diamond tools were rather restricted due to the hardness, 

this field is being explored again since the launch of 

the LaserSmart 510, the latest-generation laser cutting machines 

from Rollomatic. The laser opens up undreamedof 

possibilities such as extremely sharp cutting edges with 

radii of 0.001 mm or less. This highly productive technology 

delivers outstanding quality and can speed up machining 

times fourfold. “The fact that our machine completes 

the entire process in a single step saves time and significantly 

increases productivity,” said Sven Peter, laser 

product manager at Rollomatic. “While it used to be almost 

impossible to create sharp and defined cutting edges 

on CVD-coated hard metal tools with repeat accuracy, this 

is no longer a problem thanks to our new lasering technology. 

This opens up entirely new application fields for this 

type of tool.” 

Well trained, optimally operated 

It is not the grinding machines alone that ensure efficiency 

and highly desirable tools, but first and foremost the people 

who design these tools and deploy them highly effectively 

on the Rollomatic machine. “Since it is becoming increasingly 

difficult to find high-quality, skilled personnel, we 

have launched a comprehensive, modular tool grinding 

training program,” says Damien Wunderlin. As part of this 

program, Rollomatic offers numerous courses each year 

con ducted by highly qualified, multilingual experts, both 

on the customer's premises as well as at its training centers 

in Switzerland, the USA, Japan, Taiwan, Thailand and 

China. The courses cover everything from grinding and 

maintenance to lean production, laser technology and robotics. 

Whether GrindSmart ® , GrindSmart ® Nano, Laser- 

Smart or ShapeSmart ® , special learning units and qualification 

levels have been created for all Rollomatic types. 

“This means that everyone gets their money's worth, whatever 

their level of knowledge. Our specialists have shown 

many an expert operator who thought they knew ‘their’ 

machinery inside and out lots of little tricks that have occasionally 

led to a decisive breakthrough in tool design or 

the grinding process,” states Damien Wunderlin happily. 

A visit with added value 

Rollomatic has developed an impressive portfolio of tool 

grinding solutions as well as innovations in laser technology 

and cylindrical grinding. “Fast-moving sales markets, 

new competitors and personalized products require more 

flexible production systems - and a faster response to customer 

requirements. This is why we have created a complete 

package focusing on outstanding precision and value. 

By combining these products with smart automation solutions, 

customers can now build a production environment 

that is autonomous and highly efficient and delivers ultrahigh 

quality,” says Damien Wunderlin. 


The ShapeSmart®NP50 cylindrical grinding machine offers 

greater flexibility, faster configuration and improved surface 

qualities. It can also be easily connected to other Rollomatic 

grinding machines to form a “smart factory network” 

further information: www.rollomaticsa.com 


45


Jeremy Bunting, founder of Facet Precision Tools, 

talks about his company and its investment 

in ANCA machines 

Growing up in the cutting tool industry 

Jeremy Bunting, Managing Director of 

Facet Precision Tool grew up in the cutting tool 

industry, getting a hands-on education from 

a young age and then using this experience to 

start his own business. From laying out a brandnew 

manufacturing centre; to shaping and promoting 

Facet’s reputation; to training up a high 

performing team who are passionate about the 

craft of cutting tools - Jeremy has built the foundations 

for success. 

Jeremy begins: “I started designing my first tools at age 

14 in America as part of 

the family business, using 

manual grinding as well as 

conventional grinding to 

manu facture tools. After 

that I moved on to the applications 

side - getting exposure 

to feeds and speeds 

and eventually moved to 

Europe. In Europe I worked 

for different tooling manufacturers, 

seeing dif ferent 

approaches to manufacturing 

and precision tooling.” 

“I started Facet Precision Tools in 2015 primarily to service 

the aerospace and automotive sectors. Both these 

markets require special tools with distinct needs. At Facet 

we produce PCD, carbide cutting and coated carbide tools 

through distributers and direct to customers. Based in 

Germany we sell locally as well as to France, England and 

Spain. Through distributers we service Africa, Sweden, 

Turkey, Hungary, Austria, Italy and Mexico.” 

“It's challenging starting a new business. We had products 

in mind and were in a unique position where we 

could decide if these are our target markets - what machinery 

and equipment do we need? I considered my 

past experiences in the industry and how can I apply any 

learnings to the future. When we entered the market, I 

wanted to have high quality equipment, robust manufacturing 

processes and be producing market leading cutting 

tools.” 

“Since opening we have been growing steadily, in fact 

last year we doubled our sales. As we expand we are looking 

at how we can attract more customers, consider if 

we need to add additional products and as many people 

in the industry experience - are always looking for 

good people.” 

Establishing grinding capabilities 

“After deciding on a shop floor blue print, we invested in a 

range of ANCA machines with two MX7 Linear’s, an FX7 

and an EDGe as well as other equipment. We use the MX7s 

primarily for automotive tooling as they work well when 

grinding tools with larger diameters of 20, 25 and 32. We 

also run a lot of pocket grinding for PCD cutting tools on 

this model. The MX7 has a lot of horsepower that allows 

us to grind these tools in a very stable way. We use the FX 

for high volume carbide tooling. As an extremely rigid 

and thermally dynamic, stable machine I can rely on it to 

grind highly repeatable cutting tools.” 

“On the MX7 we have an 

ANCA spindle speeder that 

allows us to achieve higher 

rpm. We worked with ANCA 

to adjust the software to be 

able to provide a better stable 

pocket and a more accurate 

pockets in our grinding 

process.” 

“On the EDGe we manufacture 

PCD tools. In the 

past couple years we have 

been developing PCD vein 

tools with our own blanks and cutting tool designs - working 

through and refining our processes. The EDGe has allowed 

us to have a high degree of accuracy when trying 

to grind a lot of the geometries. I found that as a process, 

erosion enabled the repeatability and the quality we were 

looking for. We also added a vision camera system on the 

EDGe, allowing for a quick inspection inside the machine, 

to get higher repeatability and better quality versus taking 

it out of the machine, and putting it back in.” 

“And then there is ANCA’s 3D Cimulator program. Up 

to 95 % of the designs and problem solving are done on 

the simulator; testing the grinding process, reviewing and 

modifying before you go into a machine. It is our strongest 

tool to increase efficiency and reduce waste and that 

is a major help to our profitability. For example, carbide is 

extremely expensive where you can be paying from 400 

Euros for a 32 mm standard rod.” 

“The simulator also shows estimated grinding times which 

has been a great tool for us to reduce cycle times. Last time 

it took us, for example, 20 minutes to make this tool, but 

after considering a new idea or different approach we can 

reduce that time to 18, 17 or even 15 minutes all through 

experimenting in a simulated grinding environment.” 



“We have touch probes on all the machines that allow us 

to easily change wheel packs, qualify the wheel and start 

moving quickly. It also allows us to remove human error 

and ensures a higher finished quality. To be able to dress 

and probe the wheel, picking back up where you left off 

without having to change the set up is very advantageous.” 

“One of the main reasons we love the ANCA machines is 

because of the software. We have found it to be extremely 

flexible and at Facet we don't use a lot of the standard 

ANCA programs and designs and instead do a lot of our 

work in profile editor, changing angles and profiles to 

meet the tool designs that we need. My Dad always said 

that ANCA was a software company that built a machine.” 

Specials are a relationship business - 

requiring communication and trust 

“As we build our company we want to be known for quality. 

From the start we have been trying to build our reputation 

for offering high quality tools rather than just entering a 

market and throwing anything out there and seeing what 

sticks. We are methodical in our approach to manufacturing 

certain tools or entering a marketplace or approaching 

certain things. Even if this means we are a bit slower and 

more tactful.” 

“Just as important, is our responsiveness to the customer 

through deliveries and application support. These are the 

foundation of our company. We start by listening - what 

does the customer want to achieve, am I understanding 

their needs correctly? Then I consider how the product 

could be improved, can we make other recommendations. 

We turn that request into a tool design that is checked by 

the customer.” 

“In aerospace, a common misunderstanding is the need 

for standard tools. Tools for aerospace require different 

lengths, diameters and applications. There is also a high 

requirement for accuracy, in Europe for example, we find 

aerospace have applications that need to be measured to 

a couple of microns and use a variety of methodology to 

make holes in different materials. It is a challenge making 

a product meet quality standards while working across a 

range of material applications.” 

Building a team of craftspeople 

“I think working in speciality tools excites an element of 

craftsmanship. Every day is different, and you can take 

pride in your work, was it correct, was it to print. That is 

why we look for a person who is flexible, shows an ability 

to learn, grow, and absorb information.” 

“I train everybody in my plant like they've never seen 

a grinding machine before. We invest time to build their 

knowledge base to understanding the manufacturing and 

measuring equipment. Again, partially because we're into 

specials where every tool design is different, we don't have 

pre-written programs.” 

“I think one of the best characteristics of a toolmaker is 

an attention to detail. Often people can become over invested 

in the productivity side - how many parts can I get 

through, how fast can I get them through the line. I train 

my team to be focused on the quality of the tool first and 

productivity second. And to meet these expectations of 

quality you have to have a high attention to detail. Just 

as important is to develop your team to have a passion for 

grinding. The more passion someone has for the product, 

the more likely they are to stay. Teaching your employee 

how to make a better-quality tool feeds their creativity and 

teaches them it is ok to have your own approach and style. 

At Facet we have an open dialogue with our teams of why 

we do the things that we do.” 

“I think there will always be a need for niche and special 

products and that means more special cutting tools. 

That's one of the reasons why we were very comfortable 

moving into this industry. So as materials change - if it's 

more glass, carbon composites or aluminium - we're in 

a good position to move with the market and respond 

to those changes. I have established the foundations of 

Facet Precision Tools to be agile with design expertise, 

workforce skills and manufacturing capabilities. We can 

and do adapt and invest in the machinery or develop our 

knowledge so we can meet the markets’ changing needs 

rather than focusing on materials.” 

ANCA Europe GmbH: GrindTec 2020, hall 7, booth 7045 

further information: www.anca.com 

http:// facetprecision.com 


47


Entering a demanding market niche 

HSC milling: highly productive, high-volume 

production for surgical instruments 

Surgical instruments are high-precision 

products that are manufactured with great care, 

usually in small quantities. The structures and 

equipment of manufacturers specializing in these 

products are therefore designed above all for a 

high level of flexibility in retooling. 

A separate process chain should accordingly be set up for 

one-time products in large quantities. The key element is a 

two-spindle machine from Schwäbische Werkzeugmaschinen 

GmbH (SW) with very high repeat accuracy. An assess - 

ment report. 

“The requirements are high and the competition is hard 

in manufacturing of precision mechanical surgical instruments,” 

confirms Frank Pauschert, Regional Sales Manager 

of SW, Schwäbische Werkzeugmaschinen GmbH in Waldmössingen, 

Germany. His customers include a company 

in this sector that has grown from modest beginnings 

when it was founded in the 1980s to become a mid-sized 

enterprise, with about 130 employees. Currently about 

1,000 different utensils are manufactured for a wide range 

of surgical applications. All instruments come complete 

and ready for use. The individual parts are made of premium 

biocompatible materials such as stainless steel and 

are manufactured in machining processes. Despite the use 

of modern NC-controlled machine tools, manual operations 

make up a great deal of the manufacturing process 

for these instruments, because they consist of up to 40 different 

components that must be refined, surface-treated 

and assembled meticulously by hand. In addition, they are 

often manufactured with numerous variants. This necessitates 

small batch sizes and because of that, a prime requirement 

of the relevant manufacturing systems is very 

flexible retooling. Due to the extraordinary diversity of 

variants, there is also no way to work from stock, thereby 

lowering costs by manufacturing in larger batches. 

Strategy for the future: 

a challenging one-time product 

Since the manufacturer has not previously produced any 

of its own products, it is constantly compared with the 

numerous competitor products already available in terms 

of price by customers, who often have great market power. 

This limits profitability and with it future growth possibilities. 

To safeguard the future in the long-term, a decision 

was made about two years ago to enter an extremely challenging 

large-scale production project: manufacturing of 

a one-time tool for neurosurgery that is used so often that 

hundreds of thousands of units are needed annually. 

It is a type of forceps made of aluminum that can be 

used to grasp tissue components while at the same time 

stopping minor bleeding with electrical pulses. Minute 

tubes were also integrated into each arm of the forceps 

through which an irrigation fluid can be directed into the 

operat ing area. Despite its straightforward appearance, the 

instrument requires very time-consuming manufacturing 

with numerous mechanical and manual work cycles, 

all of which must meet strict quality requirements. Many 

of these work cycles have to be carried out under a microscope. 

Setting up the process chain requires extensive 

devel opment efforts as well as investments in machines 

and special equipment. Additional employees are currently 

being hired and qualified for this purpose. 

A machining center with the power 

of a sports car 

The starting point and key element of the process chain is 

an automated dual-spindle BA 321 machining center from 

SW. The system has a working area of 300 x 500 x 375 mm 

per spindle. The spindles are equipped with an HSK A63 

interface and reach speeds of up to 17,500 rpm with a chipto-chip 

time of 2.5 s. The tool change system has a capacity 

of from 2 x 20 to maximum 2 x 60 slots. 

The automation unit consists of a supply unit for the press-drawn 

sections and a drawer for depositing parts after they are separated 

source: SW GmbH 

This system is used to mill forceps halves made of aluminum. 

It has a custom-made automation unit for supplying 

material and removing milled parts. It is only intended 

for a limited range of parts, but within that range 

achieves productivity far beyond any other milling centers 

in the plant. With its horizontal, dual-spindle design, 

the new machining center delivers two completely milled 



forceps halves in just three minutes. Thanks to the automation 

system, it can do this around the clock, largely 

without supervision. The machine also features impressive 

repeat accuracy and thus quality of manufactured parts. In 

addition, it significantly surpasses the throughput performance 

of the other machining centers installed on site. 

Development partnership in automation 

We chose SW first of all because we were impressed by the 

productivity of the double spindle concept. Another aspect 

was their impeccable references as well as the rela tive proximity, 

which would mean short response and travel times 

both during the joint development phase to come and also 

for any service calls that might be needed. The initial contacts 

in the summer of 2017 led to a partnership-based collaboration 

during which the possibilities for automation 

BA 321 

The BA 321 is the two-spindle version of a series 

that is available as a one-, two- or four-spindle 

machining center depending on the task. It is 

suitable for machining workpieces made of aluminum, 

cast iron, titanium or steel. 

The heart of the monoblock is the working area with 

dimensions of 300 x 500 x 375 mm and the spindles, 

which are movable in three-axes. The spindles with 

HSK-A63 interface reach speeds up to 17,500 rpm 

with an output of 32 kW (4200 rpm, 40 % duty 

cycle) and a torque of 72 Nm. The spindle distance is 

300 mm. The weight of the system is about 8500 kg, 

while the standard installation dimensions are 

3.60 x 3.13 x 6.00 m (w x h x d). The series 3 is available 

as a single-station machine or with a double 

swivel carrier. 

The feed of the three-axis unit is provided by sturdy 

ball screw drives, with rapid traverse axis reaching 

speeds of 65/75/75 m/min (x-, y-, z-direction) and axis 

acceleration rates of 10, 10 and 15 m/s 2 respectively 

with a maximum feed force of 8000 N. The pick-up 

tool changing system has a capacity from 2 x 20 to 

max. 2 x 60 tools in the two-spindle variant. Tools up 

to Ø 70 mm (160 mm with free adjacent slot) with a 

maximum length of 275 mm and a maximum weight 

of 7.5 kg can be picked up. The chip-to-chip time is 

about 2.5 s. The Sinumerik 840 D sl, Bosch Rexroth 

IndraMotion MTX or Fanuc 30i are available as 

control unit. 

of machining processes was clarified. This was followed by 

joint design and development of a special machine based 

on the model BA 321. 

Special press-drawn sections in three different dimensions 

are used as raw material. The forceps halves are 

carved out of the sections and are not separated by sawing 

until the last work cycle. This neatly sidesteps clamping 

problems with the extremely slender and delicate forceps 

halves from the outset. The final saw cut is made so that 

a minimal amount of burr remains to prevent the pieces 

from falling down. Otherwise the very delicate tips of the 

forceps could be damaged. 

The forceps are removed by special adapters loaded into 

the spindles from the tool maga zine. They are used to hold 

the forceps parts and break off remaining burrs. Then 

they are deposited individually on a transport drawer and 

moved by conveyor belt to the removal station, where they 

are manually inserted in basket racks for the next work 

cycles. “The joint development of automation was very 

efficient,thanks to the professiona lism of both teams,” 

recalls Frank Pauschert. 

Delivery and commissioning 

Joint development and project planning as well as setup 

and trials up to acceptance lasted until June 2018. The necessary 

tools were implemented during this phase and an 

initial NC program was created based on customer requirements. 

After acceptance was completed, the system was 

placed in operation at the operating site in June/July 2018. 

Since then there have been tests as well as programming 

for a total of 18 product variants. The actual ramp-up 

began in November 2018. Production has already been 

running in 24/6 operation since March 2019, with the system 

sometimes running for up to a week with no human 

interaction other than supplying material and removing 

finished milled parts. 

Satisfied with quality, support and service 

Thanks to "life startUp" production monitoring in the first 

week after commissioning, the employees became familiar 

with operating the machine quickly and were able to work 

independently with it. With “life data”, an online service 

of SW, the machine is continually connected online 

to SW, where essential machine parameters are moni tored 

nonstop. If problems come up, action is taken immediately. 

Good use has already been made of this service, as the machine 

operator was supported by remote diagnostics. 

“life help” also turned out to be very helpful: when 

problems occasionally came up, it provided quick and very 

competent consulting, and if a service employee was needed 

at all, he was often on site for less than an hour. Without 

this service there is much that would not have worked, 

or would have taken much longer. An additional BA 321 

has already been ordered. 

further information: www.sw-machines.de 


49


Where craftsmanship and 

high-tech go hand in hand 

For over a century, Okuma has been developing 

grinding machines for the highest quality demands. 

Though a lot has changed since the beginning, 

some aspects remain the same. Okuma CNC 

grinders still achieve their high precision, productivity 

and longevity due to a symbiosis of craftsmanship 

and state-of-the-art technologies. 

Okuma is the only single-source CNC provider in the industry 

to develop and produce all hardware components, 

the controls and the software for the machine tools inhouse. 

The development and production from one single 

source leads to a perfect combination of hardware, software 

and electronics. Due to their outstanding precision 

and high productivity, the grinding machines can be 

found in several industries. They are used for a wide range 

of materials including soft, high-strength and temperature-resistant 

materials as well as sintered alloys, Inconel 

or chrome-plated workpieces. 

Craftsmanship for highest quality 

In addition to the modern technologies that Okuma is 

constantly developing and optimising, the machine tool 

manufacturer also relies on skilled craftsmanship that 

has become rare. In the CNC grinders, for example, handscraped 

sliding surfaces are used on the guideways and 

mounted components. The manufacturing process of hand 

scraping is very time-consuming and requires a high degree 

of skill and experience. Nevertheless, it is worth not 

neglecting this demanding manufacturing method, as the 

resulting sliding surfaces have a degree of durability, precision 

and quality that could not be achieved with other 

methods. With the exceptionally long service life and 

availability of the machines, Okuma ensures that the total 

cost of ownership (TCO) remains as low as possible. 

Okuma grinders possess 

hand-scraped sliding surfaces 

that help to achieve extreme 

precision and longevity 

Hand scraping, as it is used 

by Okuma, is extremely 

time-consuming and requires 

a lot of experience and skill 

The Okuma OSP-P300GA 

control was specifically 

devopled for CNC grinders 

and allows for ergonomic 

as well as efficient 

operations 

In-house developed control 

facilitates operations 

All Okuma CNC grinders are equipped with the in-house 

control OSP-P300GA, which was developed specifically for 

grinding applications. The control has an intuitive user 

interface, and very little user input is required. In addition, 

the control is easy to customise and can be modified 

and individualised with apps allowing for ergonomic and 

productive workflows. An example for this is an app for 

determining the optimal dressing parameters, which can 

be used to perform dressing simply, quickly and with highest 

precision. 

All-in-one processing from a single source 

In addition to stand-alone standard machines, Okuma offers 

complex production cells. This not only means an 

automation of the grinding processes. Rather, it covers the 

entire machining of a workpiece including turning and 

milling operations on Okuma machines. Users benefit from 

the consistently high manufacturing quality of Okuma 

solutions and only need to be familiar with one type of control. 

As a result, the Okuma solutions can be used for a wide 

range of applications, and only one operator is needed 

to control and monitor the entire manufacturing cell. 

Especially in times of a shortage of skilled workers, this 

proves to be a considerable advantage. 


further information: www.okuma.eu 


A wide variety of 

automation solutions 


The following write-up gives you an exciting 

insight into the world of automation. From the entry-level 

model to the customized solution, everything 

is offered and implemented. 

The history of automation began when people at work 

started transporting bags and other goods from one place 

to another using human chains, rather instead of individually. 

One of the best-known forms of automation was 

invented by Henry Ford, with the assembly of complete 

vehicles on an assembly line in 1913. 

STUDER offers its customers a wide range of automation 

solutions. Loaders are available in various price ranges. 

The more functionality the loader needs to offer, the more 

complex the loading model becomes. 

STUDER easyLoad as a suitable entry-level model 

The entry-level models are characterized by solid craftsmanship. 

They primarily provide a low-cost option for 

feed ing and removing the desired parts to and from the 

grinding machine. For the machine types S33, S31, S22 

and S41, a loader solution is offered on the basis of a portal 

loader system with V-gripper. The STUDER easyload loading 

system is suitable for shaft components up to a part 

length of 300 mm and a gripper diameter of 4 to 30 mm 

(max. interfering contour - Ø 50 mm); it therefore covers 

the majority of the part spectrum produced on these machines. 

The parts are supplied via a standardized, adjustable 

synchronized conveyor. The enclosure for the base 

module, which has been adapted to suit the machine 

design, enables safe and clean operation of the system. 

flexLoad - the loader from the USA 

A strong trend towards automation is also 

evident in the USA. In response, UNITED 

Grinding North America has developed the 

flexLoad loading system. The flexLoad - the 

name stands for flexibility - comprises of a 

six-axis robot, which can move into the 

machine on a seventh axis for workpiece 

changeover. The robot is currently available 

for the three STUDER models S33, S31 and 

S41 in the USA. 

Additional functions are 

available from the mid-range 

In the automation mid-range, where there is still an emphasis 

on standardization, STUDER also offers suitable solutions 

in collaboration with external suppliers. Additional 

functions such as deburring, brushing or re-measuring 

ground parts can be offered for automation systems in the 

mid-range. 

For example Wenger Automation & Engineering AG, in addition 

to the WeStack cell, which is responsible for the automation 

per se, also offers the WeSpeed cell. As the name 

suggests, this automation solution ensures quicker loading 

and unloading of parts on STUDER cylindrical grinding 

machines. The WeFlex is the flexible all-rounder among 

the Wenger automation cells, because 

the replaceable gripper bodies enable 

changeover from shaft to chuck parts 

in a flash. 

The sky is the limit 

As with cars, there are no upper limits 

for automation solutions. STUDER has 

implemented many different combinations 

of machines and technologies in 

the past and will also endeavor to do 

so seamlessly in the future. Other additional 

functions, such as reading and 

marking codes on grinding parts as 

well as sorting them, pre- and re-measurement 

between grinding cycles and 

match grinding, are just a few of the 

options that can be offered. 


STUDER easyLoad for external and universal cylindrical grinding machines 

further information: www.studer.com 


51


The new EMAG systems: 

Complete turnkey solutions 

from a single source 

The production of comprehensive manufacturing 

solutions from a single source is the main 

requirement for many mechanical engineering 

production planners. 

Typically, a general contractor would be responsible for the 

development of a complex line of interlinked machines 

with a variety of technologies. This provides the manufacturing 

company with two major benefits: the overall planning 

is easier (of the new factory) and a production partner 

that guarantees a perfectly designed, flexible, manufacturing 

solution, even for the most complex production 

situation. For years, the EMAG Group has been this partner, 

as it is one of the few machine builders that covers the 

entire process chain from soft to hard machining. Now, 

the experts are taking the next step with the creation of 

EMAG Systems and combining their project engineering 

expertise. The new company is the perfect partner for creating 

turnkey solutions, and is responsible for the overall 

project - combining the experience and knowledge of the 

various EMAG branches when necessary. 

For example, e-mobility: here, the requirement for 

increased quantities is currently shifting the focus to the 

establishment of comprehensive production systems. Ultimately, 

this is the only way to be able to produce complex 

components such as rotor shafts or differentials in a process-consistent 

and cost efficient manner. In the interlinked 

systems, for example, soft machining, hardening 

and hard machining take place in direct succession and 

numerous technologies from turning, drilling and milling 

to induction hardening and grinding are used. “When 

designing a complex system like this, there are naturally 

many questions during the planning phase”, explains 

Bern hard Böttigheimer, Managing Director of the new 

EMAG Systems. “For example, users must understand the 

precise benefits and performance limits of the various tool 

processes, opportunities for the component assessed and 

a reliable process developed on this basis. To compile all 

of this information, the user must have access to a large 

amount of internal technological expertise. At EMAG, we 

have been working toward this for years - we have a variety 

of core processes within the Group, and are also developing 

in-house automation technology.” 

Over the past couple of 

years, EMAG has enjoyed 

growing success with 

turnkey manufacturing 

solutions 

Bernhard Böttigheimer, 

Managing Director of the 

new EMAG Systems: 

“The demand for complete 

turnkey production systems 

is growing. We provide 

extensive expertise for 

this task” 

Combined system expertise 

With all of these tools at their disposal, EMAG has been 

enjoying growing success in the production of turnkey 

manufacturing solutions in recent years. The mechanical 

engineering company even underwent an audit by a major 

OEM, in which all processes and structures relating to the 

development of large production systems were successfully 

examined. The specialists regularly provide proof of 

their system expertise outside the automotive industry, as 

demon strated by various solutions for oil production technology 

manufacturers. In the past, experts within the individual 

EMAG companies performed the corresponding 

pro ject management. Why is EMAG Systems now taking 

on this task globally? “We are convinced that this business 

area is becoming increasingly important. The demand for 

complete production systems is growing because the range 

of products and parts is also increasing at many supplier 

companies and OEMs. This is putting more demand on 

production systems to be more flexible, and project engineering 

needs are being outsourced by many companies”, 

says Bernhard Böttigheimer. And for these customers, 

EMAG Systems provides a central point of contact with experience 

in comprehensive turnkey production. These specialists, 

based in Salach, Germany, will examine each inquiry 

in detail, and then determine which technologies are 

needed for the project. With this information they will 

form a project team, consisting of engineers from different 

EMAG companies - this team will work together to form a 

completely customized solution for the project. 

Although EMAG Systems may be new, the team is not! 

There is a variety of experts from within the company who 

have been responsible for similar projects for EMAG in the 

past. With this team, customers will benefit from the experience 

and in-depth knowledge of all of the Group’s technologies. 

Within this new organization, the expertise of the 

employees will be combined, and the internal processes 

will be simplified. This allows those at EMAG Systems to 

focus on providing customers with a comprehensive process, 

while the individual EMAG companies focus on their 

specific technologies. 



Initial success confirming the path 

Overall, the EMAG Systems experts see their market opportunities 

as very positive. After all, in the automotive industry, 

for example, many supplier companies must position 

themselves much more broadly and establish independent 

production solutions for a larger number of different drive 

technologies - from the classic “combustion engine” and 

hybrid solutions to completely electric. “In this industry, 

the demand for our resource planning expertise is growing 

quickly” explains Bernhard Böttigheimer. A second factor 

in the success of EMAG Systems is Industry 4.0. After all, 

Smart Factories that increase the productivity of a location, 

or improve process reliability are impossible without comprehensive, 

linked systems. This is where EMAG Systems 

and its project engineers play a critical role. A variety of cur- 

Turbocharger shaft: 

the EMAG Group 

controls the entire process 

chain from soft to hard machining and 

therefore repeatedly acts as a general contractor 

EMAG Systems - teamwork creates the perfect line solutions 

rent projects shows that this full scope approach is working 

in the market, especially in e-mobility. For example, 

EMAG is currently developing two production systems for 

machining a rotor shaft for European customers. “We are 

clearly on the right track”, sums up Bernhard Böttig heimer. 

“With EMAG Systems, we intend to bring our longstanding 

project engineering expertise to the market in a 

selective manner, while continuing to grow over the next 

few years and at the same time pressing ahead with the 

technological development of production systems. We are 

in an ideal position for this.” 


further information: www.emag.com 

Haas grinding machines: 

Next level grinding 

With the exhibition appearance at GrindTec 

Haas is opening a new chapter in its company 

history. Under the motto Next Level Grinding, the 

visi tors will get to know new efficient solutions. 

On nearly 600 m² a variety of high-tech grinding machines 

can be seen in action. In addition, there will be live 

presentations, goal-oriented consulting sessions and lots of 

new businesses. At this year's GrindTec Haas will present 

three highly exciting subject areas to its visitors. Not from 

the top down, but in direct dialogue. 

Next level innovation 

Haas opens up new perspectives in grinding processes. 

The Next Level Practice demonstrations on the Multigrind ® 

grinding machines are real high-tech solutions and in 

total certainly the most spectacular and innovative to see 

at GrindTec 2020. 

Next level digital 

Multigrind ® Horizon becomes the most important component. 

Haas shows how to benefit from digitalization today, 

with software solutions that make business more economical, 

flexible and successful. Haas builds the bridge between 

humans and machines and visualizes how analog and 

digi tal can merge. 

Next level automation 

Haas shows automated manufacturing processes and how 

its customers benefit directly from the new flexibility, efficiency 

and quality. 

Haas always offers its customers individually designed 

turnkey solutions. The highly flexible grinding machines 

from the Multigrind ® series are turned into high-tech tools 

by software solutions. One software innovation at the fair 

that is se cond to none also includes: a simulation soft ware 

that is not a simulation software in the strict sense. 

Multigrind ® Styx shows the real data instead of simulating 

them on the basis of triangulation, turning simulation 

into visualization. Thanks to ray tracing all grinding processes 

can be completely mapped in advance. Instead of reconstructing 

surfaces, Multigrind ® Styx displays all shapes, 

pixel-precise and without restrictions. It shows the workpiece 

data down to the smallest detail. Inequalities and 

transitions, even ripples in the workpiece surface, are displayed 

and can be corrected before the grinding operation 

starts. This saves time, material and nerves. 


further information: www.multigrind.com 


53


Liechti Engineering drives efficiency 

in turbine blade 

Manufacturing with automated adaptive 

milling technology and new minimal-quantity 

lubrication process 

A historic and global ramp-up in aerospace 

component production is underway, and turbine 

blade manufacturers are under pressure to keep 

pace while maintaining absolutely flawless quality 

and highest efficiency. As a GF Machining 

Solutions brand and the worldwide leader in fiveaxis 

airfoil machining solutions for aerospace and 

power generation industry turbine manufacturing, 

Switzerland-based Liechti Engineering continues 

to push technological boundaries with its 

automated adaptive blade Milling technology and 

its recently benchmarked minimal quantity lubrication 

(MQL) concept. 

Automated adaptive blade Milling is just one of the many 

areas where Liechti Engineering adds value for manufacturers 

of high-value aerospace components: while adaptive 

Milling is nothing new, the autonomy that Liechti brings 

to the table is a true game changer. With its automated 

adaptive blade Milling, the workpiece is measured in the 

machine and the TURBOSOFT computer-aided manufacturing 

(CAM) software generates and optimizes the 

tool path. As a result, the Milling machine automatically 

begins to machine the blade - no human interaction required 

- at highest productivity and quality. 

This premium solution, which is fully integrable with 

flexible manufacturing systems (FMS), represents a major 

stride forward for blade manufacturers made possible by 

Liechti’s established airfoil machining expertise and its 

TURBOSOFT CAD/CAM software. The automated adaptive 

blade Milling technology innovated by Liechti saves time, 

boosts productivity, and takes human error out of the 

machining equation - all of which have a significantly positive 

impact on efficiency. 

MQL processing 

At the same time, Liechti’s innovative MQL processing has 

been recently benchmarked at Blaser Swisslube, an internationally 

active developer and producer of high-quality 

metalworking fluids, based in Hasle-Rüegsau, Switzerland. 

In collaboration with Blaser Swisslube and Solothurn, 

Switzerland-based machining specialist Walter AG, Liechti 

proved that its MQL concept optimizes the Milling of 

steel turbine blades and takes machining efficiency to a 

new level. 

MQL takes a small amount of lubricant through the spindle 

on the cutting tool - right where it’s needed - so there 

is no loss of efficiency. In one portion of the benchmarking 

at Blaser Swisslube, MQL proved its added value in the 

machining of X20 chrome steel blocks, demon strating 

both reduced flank wear and very good surface finishing. 

In additional testing carried out at Liechti Engineering in 

Langnau, Switzerland, a Liechti Turbomill 1400i was used 

to process hard-to-machine X20 chrome steel - a true test 

of the MQL process. The conclusion: thanks to MQL processing, 

cutting edge wear was reduced and tool life was 

extended. In fact, tests showed that polishing with MQL 

can reduce tool wear by up to five times compared to standard 

metalworking fluid. 

All cooling methods have their advantages and disadvantages, 

and that’s where MQL offers even more gamechanging 

potential: by having both metalworking fluid 

and MQL at their disposal, blade manufacturers have 

greater flexibility because they have the right process for 

any material or challenge that comes their way. 

All Liechti machines currently in the field can be retrofitted 

with MQL and this success-triggering innovation 

can be integrated into new Liechti machines as well. 


further information: www.gfms.com 


components 

Metall-Chemie GmbH & Co. KG out with corrosion inhibitor TC ® 85 

Lubricant manufacturers count on quality 

and sustainability 

Customers in the global lubricant industry 

are increasingly relying on sustainable additives. 

Metall-Chemie GmbH & Co. KG can tell this 

from the success of the TC ® 85 inhibitor. The additive 

reliably prevents corrosion when used in almost 

all water-based lubricating greases, synthetic 

and semi-synthetic cooling lubricants and biodegradable 

hydraulic fluids. Within a short time, 

sales of TC ® 85 by the Hamburg-based lubricant 

additive specialist have almost tripled - with an 

upwards trend. 

TC ® 85 caters to responsible producers 

Dr. Piotr Tkaczuk, chemist and Head of Business Development 

at Metall-Chemie, attributes this to a change in 

demand from industrial customers: “Quality is a matter of 

course for our customers. Responsible entrepreneurs are 

paying more attention to positive secondary characteristics 

such as the environmental impact in their purchasing 

activities”. 

TC ® 85 is essentially a trifunctional organic carboxylic 

acid sold in the form of a dry powder. The corrosion inhibitors 

TC ® 50 and TC ® 65 from this product family have 

proven their worth in numerous formulations with lubricant 

manufacturers; their sales remain roughly stable. The 

sales success of TC ® 85 is due to its highly concentrated 

active ingredient. The white dry powder contains 85 % active 

ingredients in the ready-to-dose mixture. Metall-Chemie 

has been able to reduce the moisture content to 15 % 

through innovative production management. 

Advantages for CO 2 

footprint and processing 

“The advantages are obvious,” says Dr. Tkaczuk. “Less 

goods are moved in logistics. A lower transport volume in 

the supply chain improves the CO 2 

footprint.” In addition, 

the higher concentration of active ingredients saves storage 

capacity. Thanks to the highly concentrated material, 

buyers in the lubricants industry also have to re-order less 

frequently. 

This significantly reduces the workload of production 

employees. Since TC ® 85 is packaged in handy bags of 20 kg 

each, filling the production tank is easier; there is less 

weight to move. 

“In addition, our corrosion inhibitor TC ® 85 is much 

more free-flowing, doesn't clump and is therefore easier to 

dose and process. Our customers even reduce their energy 

costs,” adds Dr. Tkaczuk. 

The corrosion inhibitor TC ® 85, designed by the 

Hamburg-based company Metall-Chemie GmbH & Co. KG, 

supports lubricant producers in the production of more 

environmentally-friendly cooling lubricants, lubricating 

greases, metalworking oils and hydraulic fluids 

Lubricant manufacturers can score points with their customers 

with TC ® 85. The registered trademark of Metall- 

Chemie stands for more environmental awareness and sustainability 

- and responsible companies are attaching more 

and more importance to this. 

Metall-Chemie GmbH & Co. KG is a globally operating, 

highly specialised company of the Metall-Chemie Group. 

Metall-Chemie GmbH & Co. KG sells, develops and produces 

lubricant additives for oil-based and water-based 

applications. In addition to sales offices in Hamburg and 

Shanghai, the company is directly represented by selected 

distribution partners in numerous countries. Reliable 

delivery and sustainable, high product quality have top 

priority. 

The product portfolio includes different types of lubricant 

additives for oil-based and water-based applications. 

In addition to various lubricant additives, purchasers and 

developers of the petrochemical industry will find applications 

such as corrosion inhibitors, metal deactivators, 

extreme pressure (EP)/antiwear (AW) additives or friction 

modifiers. All products are subject to constant quality controls 

and can be customised and modified as needed. 

further information: www.mc-chemie.com 


55

components 

More time to generate revenue 

Wagstaff fights information losses with Tool 

Lifecycle Management from TDM Systems. Having 

a clear overview of around 4,000 tools pays off 

for the machine and equipment manufacturer in 

savings of both time and money. 

Wagstaff Inc. plays a key role in the aluminum industry: 

The family business, which is based in Spokane, Washington, 

develops and manufactures equipment and systems 

for producing primary aluminum ingots and billets. The 

company was founded in 1946 and, since the 1960's, has 

been the market leader in aluminum direct chill casting, a 

process in which the aluminum melt is poured into a permanent 

metal mold. Since then, the company has grown 

steadily and today has subsidiaries all over the world, as 

well as over 300 customers in 58 countries. The plant in 

Spokane alone has around 133,000 ft 2 (12,500 m 2 ) and covers 

all process steps from research and development, production, 

machining, installation and testing through 

to delivery. Meanwhile, the company’s machinery has 

grown to include 30 CNC and 30 non-CNC machines. The 

number of tools in use has also risen. The increasing complexity 

presented the leading technology provider with 

several challenges. 

Second-hand information 

“At some point, around 2004, we realized how much money 

we were spending on lost information,” remembered Jeff 

Smutny, Manufacturing Engineering Manager at Wagstaff. 

Some of the tool data was in the process documents for 

each of the product lines; other data was stored in the 

CAM system and yet more data was in Excel sheets. Retaining 

an overview of this information and using it to fulfill 

orders proved difficult: “This approach was not very efficient 

and everyone seemed to have a different idea of how 

each tool was supposed to be used,” explained Smutny. 

“It was costing us time and money.” 

Another problem was communication between individual 

employees and departments. For example, information 

was not exchanged sufficiently between NC programming 

and the shopfloor. There was no central database in which 

the master data of the tools was saved. “We were relying 

on second-hand data instead of having direct access to the 

source of the information,” explained Russ Rasmussen, 

Manufacturing Engineering Technician at Wagstaff. This 

made crucial processes, such as the simulation of a workpiece, 

extremely difficult, since it was unclear whether the 

data in use was correct and up-to-date. 

The tool data management project gets 

the go-ahead 

It was a visit by Smutny to the headquarters of Walter AG 

in Tübingen, Germany, that initially triggered a significant 

change at Wagstaff. There the engineer saw that Walter 

was using the Tool Lifecycle Management (TLM) system 

from TDM Systems and was impressed by the system’s 

scope and capabilities: “It was clear that we needed a tool 

management system.” 

According to Dan Speidel, Director of Sales at TDM 

Systems, Inc., the TLM system ensures that tool data is 

available in the right place at the right time. It connects 

CAM systems, presetting and crib systems as well as CNC 

machine control systems, but can also integrate PPS, ERP 

and MES systems on the planning and execution level. “To 

do this, the system must be able to integrate data from a 

variety of sources - from the manufacturer catalog to the 

3D models developed in house - into a central data base,” 

Speidel stated. 

Thus, Tool Lifecycle Management influences the entire 

process, from tool selection through their use in production 

planning to tool use on the shopfloor. An important 

point to note here is that information gathered at each process 

step flows continuously back to the central database. 

From there, the data can be used across the entire network. 

This system was precisely what Wagstaff required. 

On the way to increased efficiency 

The first step in reorganizing to include the TDM solution 

was to define the tools, no easy task when there are roughly 

A pintle bearing for a 

navigation lock on the 

Columbia River that was 

machined on one of 

Wagstaff’s 5-axis CNC mills 

for a U.S. Army Corps of 

Engineers facility 

Aluminium billets 

(continuous cast profiles), 

which are produced in 

the factory of a 

Wagstaff customer 


components 

4,000 tool assemblies and many, many more tool items. 

However, this is one step that was definitely worth it, accor 

ding to Speidel. In his experience, many companies are 

content to use the generic tool models of the CAM system, 

but there is a price to pay for that. It means that, in theory, 

when the actual available tools are not recorded in any 

database, the programmer needs to leave their desk each 

time to ask the tool dispensing team or search for the 

tools in question themselves. The result: lost time. If, however, 

the programmer uses the actual tool graphics from 

the beginning instead of the generic models, then the 

guesswork and the associated uncertainty are avoided. 

If the available tools and items are recorded and listed, 

then, according to Speidel, efficiency and reproducible 

accuracy are within easy reach. 

At the tool selection stage, several more questions need 

to be asked: which tools are best suited for which process 

steps? And which combinations are particularly efficient? 

Today, Tool Lifecycle Management from TDM helps 

Wagstaff to quickly answer questions like this by providing 

the programmer with basic information about each of 

the tools and their potential applications. The system not 

only provides support in selecting the right tool for each 

NC operation; it also saves geometric and cutting data for 

every tool. It creates 3D tool graphics for NC programming 

and simulations, and saves tool lists from the NC programs 

for future use. In addition, the system saves cutting data, 

machining conditions and best practices so that tool use 

can be optimized further in the next project. 

Faster and more precise 

“These TDM functions not only offer great advantages 

when we are fulfilling repeat orders,” Smutny continued, 

“but they also help us when we face new challenges.” For 

example when dealing with a different product or application 

but the same material, the programmer can find out 

From aluminum oxide to metal 

The light metal aluminum is growing in popularity. 

No wonder that Wagstaff is growing and growing. 

The systems sold by this company produce 

primary aluminum, a term which distinguishes it 

from aluminum that has been recycled from scrap. The 

starting material is a white powder: aluminum oxide, 

which was previously obtained by refining bauxite. 

Releasing the metal from its bond with oxygen requires 

an enormous amount of electricity for electrolysis. As 

aluminum oxide does not melt until it reaches 3700 ° F 

(2045° C), it is mixed with cryolite to lower the melting 

point to 1740° F (950° C). When the process is complete, 

the aluminum melt is cast in order to make ingots or 

bars, for example. During direct chill casting, which 

Wagstaff specializes in, the fluid material is poured 

directly into a permanent mold made of metal - the 

ingot mold. Rapid cooling in the mold gives the cast 

parts a dense, low-pore structure with a smooth surface. 

This provides an ideal starting point for using 

aluminum in a wide range of industries. 

Machining of a large steel hydraulic cylinder weldment 

for one of Wagstaff’s aluminum casting product lines 

about the previous performance of the tools and assemblies. 

He concluded: “Overall we have saved a lot of time 

and increased our precision.” 

Tool presetting via the software also helps to increase 

precision. For this, TDM is working with leading presetting 

manufacturers in order to create a two-way communication 

system: during the measuring process, the systems 

can access the nominal data of each tool assembly saved in 

TDM. The measured actual data is then transferred back to 

TDM. In this way, the quality of the data can be continuously 

improved. This data exchange with TDM is carried 

out via DNC or with tool chips. Information about the required 

tools and the NC programs arrives at the relevant 

machine at the same time as the current actual data of the 

preset tools, as well as graphics, photos and/or notes. 

TDM Systems has seen that processing precise tool data 

can reduce programming and setup times by around 25 %. 

At Wagstaff programming times have also been significant ly 

reduced: according to Smutny, the company has grown 

considerably since TDM was introduced, but the programming 

team is still the same size it was in 2004. “We now 

spend more time on preparing jobs that bring in revenue 

and less time looking for information,” Smutny stated with 

satisfaction. “TDM has expanded our scope hugely.” 

“Maintaining an overview of around 4,000 tool assemblies 

and their items used to be a serious headache and 

cost us many man hours - these can now be used for valueadded 

work,” Rasmussen points out another advantage: as 

the types of cutting tools, extensions, brackets and clamps, 

etc. the company has in its crib are know on record, it has 

been possible to reduce the crib inventory and the purchasing 

volume of new tools and items. Rasmussen admits 

that the new system was not readily accepted by all colleagues 

to begin with, and many were hesitant. Today it's 

different: “One of our programmers recently said that he 

couldn’t imagine doing his job without TDM now. TDM 

has become a crucial component for success in our work.“ 

further information: www.tdmsystems.com 


57

impressum 

ISSN 2628-5444 

Publisher 

Benno Keller 

tel: + 49 (0)911 2018-200 

fax: + 49 (0)911 2018-100 

keller@harnisch.com 

Editor-in-chief 

Eric Schäfer 

tel: +49 (0)911 504 98 82 

fax: +49 (0)911 506 38 32 

eric.schaefer@harnisch.com 

company finder 

editorial 

ANCA............................................................ 46 Liebherr................................................... 40 

BOEHLERIT GmbH & Co. KG................21 LMT Tools................................................... 33 

Cecimo.......................................................32 MAPAL....................................................14, 23 

Managing Editor 

Christiane Ebner 

tel: +49 (0)911 2018-260 

fax: +49 (0)911 2018-100 

ebner@harnisch.com 

Editor 

Tanja Pinke 

tel: +49 (0)911 2018-130 

fax: +49 (0)911 2018-100 

pinke@harnisch.com 

Publishing Company 

Dr. Harnisch Publications 

Management board 

Dr. Claus-Jörg Harnisch 

Benno Keller 

Eschenstrasse 25 

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Germany 

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fax: +49 (0)911 2018-100 

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www.harnisch.com 

www.hptooling-mag.com 

Advertising Germany, Austria, Switzerland 

Thomas Mlynarik 

tel: +49 (0)911 2018-165 

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Advertising, 

North American editor USA, Canada 

Bill Kaprelian 

tel: +1 262 729 2629 

kaprep@harnisch.com 

CemeCon Inc............................................. 33 

CERATIZIT Group.....................................10 

EMAG............................................................52 

EMVA............................................................ 33 

Facet Precision Tool................................. 46 

FEPA...............................................................31 

Fraunhofer IPA.......................................... 36 

Fraunhofer IWM........................................32 

FRITZ STUDER AG..............................35, 51 

GF Machining Solutions......................... 54 

GrindTec...................................................... 30 

Haas.............................................................. 53 

Heller Machine Tools...............................32 

Hyperion Materials & Technologies... 34 

Kapp Niles............................................... 22 

LACH DIAMANT.................................16, 26 

Leitz...............................................................21 

Meister Abrasives.......................................17 

Metall-Chemie GmbH & Co. KG.......... 55 

Mikron Tool................................................18 

Multigrind.................................................. 53 

NUM AG...................................................... 34 

Okuma......................................................... 50 

PaintExpo................................................... 29 

REISHAUER AG........................................... 6 

Rollomatic.................................................. 44 

Sandvik.....................................................9, 20 

Schwäbische Werkzeugmaschinen 

GmbH (SW)................................................ 48 

TDM Systems............................................. 56 

TIGRA........................................................... 24 

TYROLIT..................................................... 39 

Vollmer................................................... 43 

Water Jet Sweden.............................. 42 

Advertising China, Hong Kong, Taiwan 

Mike Hay 

tel: +852 9096 8895 

mchhay@ringier.com.hk 

Advertising Taiwan 

Sydney Lai 

tel: +886 (0)4 232 973 18 

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Number of issues 2020 

four issues per year 

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The publisher accepts no liability with regard to 

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advertising index 

Boehlerit GmbH & Co. KG........................................................................................29 

CERATIZIT Deutschland GmbH......................................................................................5 

FRITZ STUDER AG..........................................................................................................25 

KAPP NILES....................................................................................................................19 

Krebs & Riedel Schleifscheibenfabrik GmbH & Co. KG............................................11 

Lach Diamant..................................................................................outside back cover 

Landesmesse Stuttgart...........................................................................................3 

PUK.........................................................................................................inside back cover 

Reishauer AG.......................................................................................................... cover 

ROLLOMATIC.................................................................................................................13 

TIGRA..............................................................................................................................17 

WiN........................................................................................................ inside front cover 


PROCESS TECHNOLOGY&COMPONENTS 

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Exclusive information around the pump 

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