hp tooling 2019 #2

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

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


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ISSN 2628-5444<br />

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

Machine Tools, PCD, PVD, CVD, CBN, Hard Metal <strong>2019</strong> - 2<br />

Transparent Grinding Processes<br />

HPT Titelseite 09-<strong>2019</strong>-Transparent Grinding Processes.indd 1 25.07.<strong>2019</strong> 12:02:10<br />

■ Machining structural parts for aircraft ■ High dynamic turning - the future of turning ■<br />

■ Production of involute and cycloidal gears for robotics ■ Hybrid coating for <strong>tooling</strong> ■ EMO preview ■

: Abundance of Coatings Advanced Coating Systems<br />

S W I S S Q U A L I T Y<br />

www.platit.com<br />

ALL ®<br />

nACo ®<br />

®<br />

AlCrN<br />

BorAC ® BorAT ® nACRo ®<br />

®<br />

ZrN<br />

: Hall 5 - Booth E12<br />

CrTiN<br />

CrN<br />

TiXCo<br />

®<br />

BorCo<br />

TiAlN, AlTiN<br />

nACoX ®<br />

TiAlCN<br />

TiCN<br />

TiN<br />

®<br />

X-VIc<br />

WC/C<br />


editorial<br />

Is the glass half full or half empty?<br />

Eric Schäfer<br />

editor-in-chief<br />

The opinions of economic<br />

experts differ when it comes<br />

to making forecasts for the<br />

global economy. What is<br />

certain is that trade conflicts<br />

and other political and<br />

economic turbulences are<br />

weighing on the economy.<br />

But whether the current<br />

slump in growth is already the<br />

beginning of a crisis or whether<br />

it is just a dent or even a slight<br />

weakness - as others think -<br />

the coming months will show. Although investments<br />

in mechanical and plant engineering are declining<br />

worldwide, these declines are assuming a high level<br />

in many places. Even the economic experts from the<br />

IMF (International Monetary Fund) do not agree on<br />

how to proceed.<br />

EMO, the world trade fair for metalworking, could become<br />

a trend barometer. The fair, which will take place<br />

in Hanover, in September from 16 to 21, is always an<br />

important sentiment indicator. No noticeable restraint<br />

on the part of exhibitors can be observed in the run-up<br />

to the fair. And the interest of the visitors also seems<br />

to be unbroken. This is shown by this issue of “journal of<br />

<strong>hp</strong> <strong>tooling</strong>”, which is once again packed to the brim with<br />

trade fair innovations from exhibiting companies.<br />

Once again, digitisation will be a major topic at EMO.<br />

The extent to which digital transformation will change<br />

the tool industry will be explained in the excellent<br />

article by the Fraunhofer Institute for Manufacturing<br />

Engineering and Automation. In particular, it provides<br />

small and medium-sized companies in the tool<br />

manufacturing market with a precise concept for<br />

implementing digital technologies. Further interesting<br />

technical articles can be read on “Productive PCD precision<br />

machining” and on a process that describes “Hybrid<br />

coating for the tool industry”. They show how existing<br />

processes can be further developed and perfected. In any<br />

case, the glass is half full with sustainable ideas and the<br />

right strategy.<br />

You want to read about sustainable ideas and new<br />

products even faster? Our new website has been<br />

online since July: www.harnisch.com<br />

There you will find the latest news between the print<br />

editions of “journal of <strong>hp</strong> <strong>tooling</strong>”. Take a look and<br />

convince yourself of our new online presence!<br />

Eric Schäfer<br />

editor-in-chief<br />


Schleifscheibenfabrik GmbH & Co. KG<br />

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

• Grinding Wheels in Vitrified Bond<br />

• Grinding Wheels in Resinoid Bond<br />

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

Innovative Grinding Technology since 1895!<br />

Grinding Perfection for<br />

every Process!<br />


Schleifscheibenfabrik GmbH & Co. KG<br />

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

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

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

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


table of contents<br />

cover story<br />

Black Box no more - making generating gear grinding transparent<br />

The machine tool, the <strong>tooling</strong> and the process are no longer separate entities 6<br />

materials & tools<br />

The power of carbon for lead-free machining 8<br />

The revolution in cast iron turning 10<br />

IGUANA - Evolution 2.0 - helical fluting included 12<br />

Significantly better surface finishes thanks to vibration damping 14<br />

Compression Routers in woodworking offer a superior cut 16<br />

LACH DIAMANT looks back on 95 years - second part How the story continued 18<br />

New Leitz DT Premium compact hogger 22<br />

Milling instead of polishing 23<br />

WJX - high feed milling cutters 24<br />

processes<br />

Machining structural parts for aircraft calls for purpose-built tools 36<br />

Productive PCD precision machining<br />

by Dr. Stephan Scholze, Josquin Pfaff, Dr. Karl Mayrhofer,<br />

Gunter Steckel, Jana Haas-Wittmüß and Chris Graham 38<br />

Hybrid coating for <strong>tooling</strong><br />

by Tibor Cselle, Andreas Lümkemann and Mojmir Jilek 42<br />

CERATIZIT has re-imagined turning 45<br />

Digital transformation is changing the cutting tool manufacturing industry<br />

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

Fraunhofer Institute for Manufacturing Engineering and Automation 46<br />

machining center<br />

New standard in universal external cylindrical grinding 49<br />

Two world premier grinding machines 50<br />

KERN Micro-Highest precision while milling around the clock 52<br />

Automation, digitalisation and full machine power 54<br />

The sequel to a successful event concept 55<br />

Rugged and reliable machines for high production manufacturing 56<br />

Two new HELITRONIC models 57<br />

2-spindle hobbing machine with integrated chamfer unit for E-transmission 58<br />

components<br />

Production of involute and cycloidal gears for robotics 60<br />

Up-to-date tool data from the cloud 62<br />

Dyna Test bar for spindle inspection 63<br />

Highly accurate linear sensor for rapid measurement of various surfaces 64<br />

departments<br />

fairs 26<br />

companies 28<br />

impressum & company finder 66<br />

4 no. 2, August <strong>2019</strong>

Different<br />

turning operations<br />

with only one tool<br />

360°<br />

degrees of<br />

freedom<br />

More information on:<br />

www.ceratizit.com/hdt<br />

Variable<br />

approach angles<br />

outstanding chip control<br />

Visit us:<br />

Hall 5 – B 70<br />

High Dynamic Turning<br />




CERATIZIT is a high-tech engineering group<br />

specialised in <strong>tooling</strong> and hard material technologies.<br />

Tooling the Future<br />


cover story<br />

Black box no more -<br />

making generating gear grinding<br />

transparent<br />

Modern thinking no longer considers the machine tool,<br />

the <strong>tooling</strong> and the process as separate entities<br />

Blackbox no more!<br />

Only high-accuracy gears<br />

guarantee the proper functioning<br />

and reliability of transmissions<br />

in cars, aircraft, and industrial<br />

machinery. Modern gearboxes<br />

have to deliver reliable<br />

transfer of torque at high power<br />

density, to feature low weight<br />

design and to function at low<br />

Reishauer gear grinding machine made transparent<br />

noise emission. From an economic<br />

point of view, expenditure<br />

must be low for both costs<br />

per piece and life-cycle costs.<br />

At the same time, uncompromisingly<br />

high part quality and<br />

process stability must be maintained<br />

at a constant geometrical<br />

and dimensional quality.<br />

Continuous generating gear grinding<br />

has established itself as the most<br />

productive process for the hard-finishing<br />

of high-precision gears. Generating<br />

gear grinding is based on a<br />

dressable vitrified bonded threaded<br />

grinding wheel, also called a grinding<br />

worm. In simple terms, the kinematics<br />

can be understood as a worm<br />

HPT Titelseite 09-<strong>2019</strong>.indd 1 25.07.<strong>2019</strong> 09:56:58<br />

6 no. 2, August <strong>2019</strong>

cover story<br />

Continuous generating gear grinding process in action<br />

drive that features several machine<br />

axes moving simultaneously to grind<br />

the gear profile. A high-precision diamond<br />

roll dresses the grinding worm<br />

in such a way that the wheel profile<br />

generates the final gear geometry. The<br />

generating process delivers constant<br />

accuracy at high production volumes.<br />

The high output means, however, that<br />

in-process measuring, as known in cylindrical<br />

grinding, for example, is not<br />

possible as the machine axes movements<br />

are far more complex.<br />

As the continuous gear grinding<br />

machine can produce far more parts<br />

per unit of time as a measuring machine<br />

can measure, the parts have<br />

to be measured outside the machine.<br />

Furthermore, not all parts can be<br />

measured, and users have to rely on<br />

sample measurements. However, even<br />

if the two pieces measured at either<br />

end of a sample lot prove to be within<br />

tolerance, one could never be sure<br />

if all parts of that chosen sample are<br />

within tolerance. Therefore, there is a<br />

risk that parts that are not within tolerance<br />

end up in transmissions.<br />

Reishauer not only builds machines<br />

but also manufactures the necessary<br />

<strong>tooling</strong> such as threaded wheels, diamond<br />

dressing tools, workholding,<br />

and coolant nozzles. When all these<br />

elements are in place, the grinding<br />

process can be made stable and delivers<br />

high-quality workpieces. As the<br />

Greek philosopher, Aristotle, stated:<br />

“Every tool achieves perfection by serving<br />

one, instead of many purposes.”<br />

All of which Reishauer adheres to<br />

and gives it unmatched insight into<br />

the grinding process. For this reason<br />

Reishauer can now characterize and<br />

monitor generating grinding - from<br />

workpiece to workpiece - like never<br />

before. Monitoring is not limited to<br />

work pieces. Automatic testing cycle<br />

measure and evaluate the machine<br />

tool itself. As the machine and the<br />

process have become more transparent,<br />

the title “Black box no more”<br />

was chosen for this very reason. The<br />

Merriam-Webster dictionary defines a<br />

black box as “a usually complicated<br />

device whose internal mechanism is<br />

usually hidden from or mysterious to<br />

the user.”<br />

Process monitoring<br />

The dressing and grinding intensities<br />

are measured and monitored by<br />

smart real-time data processing and<br />

tested algorithms. For each workpiece,<br />

all data generated during dressing and<br />

grinding are recorded and stored in a<br />

database and remain 100 % traceable.<br />

Using the stored process and <strong>tooling</strong><br />

data, including workpiece identification<br />

via DMC, offers the means of<br />

comprehensive analysis. Due to process<br />

interaction, and using preset evaluation<br />

limits, workpieces that exceed<br />

or fall short of these limits are automatically<br />

removed.<br />

Component monitoring<br />

Recurring automatic testing cycles<br />

measure and evaluate all the relevant<br />

grinding machine axes involved<br />

in the process, and thus enables early<br />

detection of electromechanical deviations.<br />

Maintenance costs are optimized<br />

both in terms of planning and<br />

diagnosis, and some potential EOL<br />

anomalies may be avoided.<br />

Summary of features:<br />

• OEE<br />

• production data acquisition<br />

• process data analysis<br />

• analysis of the state of<br />

electromechanical components<br />

• usage data handling (RFID)<br />

• communication with measuring<br />

machines (GDE, and others)<br />

• preventive maintenance<br />

• 100 % traceability<br />

The Reishauer Process Monitoring<br />

System will be first shown to the<br />

public at<br />

EMO <strong>2019</strong>, hall 26, booth C109.<br />

Walter Graf, Reishauer AG, August ‘19<br />

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

no. 2, August <strong>2019</strong><br />


materials & tools<br />

The power of carbon for lead-free machining<br />

Considerable savings on tool costs using carbon-based coatings<br />

More and more manufacturers,<br />

and the automotive industry<br />

in particular, will have to face<br />

the difficult challenge of machining<br />

lead-free brass and copper<br />

materials in order to remain successful<br />

in future. But forwardlooking<br />

suppliers of precision<br />

ma chining tools such as Werkö<br />

and coating specialists like<br />

Oerlikon Balzers have good<br />

news: specially designed tools<br />

coated with BALINIT HARD<br />

CARBON can stop tool costs<br />

tripling or quadrupling.<br />

The call for help came in 2015:<br />

a plumbing equipment manufac<br />

turer and Werkö customer<br />

reported hugely increased tool<br />

use in production of turning<br />

workpieces, which now had to<br />

be made from lead-free brass in<br />

accordance with the German<br />

Drinking Water Ordinance. For<br />

this and other reasons, Werkö<br />

has since focused on responding<br />

to the difficulties of machining<br />

these materials.<br />

Machining lead-free non-ferrous<br />

me tals remains a niche market. It came<br />

into being partially as a consequence<br />

of the EU Drinking Water Directive<br />

98/83-EC, which restricted the lead<br />

con tent of drinking water to 10 mg per<br />

liter from 2013 for environmental reasons.<br />

The RoHS and other similar directives<br />

have also come into force in<br />

many countries around the world to<br />

limit the use of lead in electronic devices<br />

and components. However, it is<br />

the ELV (end-of-life vehicles) directive<br />

2000/53/EC that will have the biggest<br />

impact in future, as its exemption for<br />

copper alloys containing up to 4 %<br />

lead expires in July 2021.<br />

Unless the exemption is extended,<br />

automotive manufacturers will soon<br />

have to machine more and more leadfree<br />

or low-lead copper. As people increasingly<br />

switch to electric and hybrid<br />

vehicles, which use up to 3.5<br />

times more copper<br />

than vehicles<br />

with internal<br />

combustion<br />

engines (not to<br />

mention the electric<br />

charging stations,<br />

which<br />

need copper for<br />

contacts and<br />

plugs), one study<br />

suggests that the<br />

demand for copper<br />

will rise from<br />

185,000 tonnes in 2017 to 1.74 million<br />

tonnes in 2027.<br />

“Companies processing copper and<br />

brass need to prepare sooner rather<br />

than later,” says Vicente Madrid,<br />

Pro duct Manager and Direct Sales<br />

Team Leader at Werkö in Königsee,<br />

Thuringia. “Our plumbing equipment<br />

customers found that switching to<br />

lead-free brass quadrupled their tool<br />

costs and led to long cycle times,<br />

damaged tools and lots of scrap.” One<br />

reason is that the lead which was previously<br />

in the brass made machining<br />

and chip breaking considerably easier,<br />

and another is that some lead-free<br />

substitute materials increase tool wear<br />

through smearing and produce long<br />

cylindrical chips, making the process<br />

less safe. “This is a revolution in machining”,<br />

says Madrid.<br />

After intensive testing in their application<br />

center, in 2016 Werkö eventually<br />

developed a successful solution<br />

using a special tool with a clever spiral<br />

design and geometry. And when classic<br />

PVD coatings proved ineffective,<br />

BALINIT HARD CARBON, supplied<br />

by the company’s long-term partner<br />

Oerlikon Balzers, produced successful<br />

results at the second attempt. For Rico<br />

Fritzsche, Segment Manager Cutting<br />

Tools, this is confirmation that Balzers<br />

is on the right track: “Since 2014<br />

we have gained invaluable expertise<br />

in machining lead-free materials in<br />

colla boration with our business and<br />

research partners.”<br />

Throughout this development<br />


has consistently proved the perfect<br />

choice. The carbon coating is chemically<br />

inert, prevents built-up edge formation<br />

and sticking, restores chip<br />

flow and is also suitable for dry machining<br />

thanks to its high hardness<br />

(5000 HV) and low friction coefficient.<br />

Three options are available,<br />

with different coating thicknesses depending<br />

on the application, and in future<br />

customized pre- and post-treatment<br />

will enhance chip flow and cutting<br />

pressures for shank-type tools.<br />

Combining these advantages with<br />

the new, specially designed tool resulted<br />

in extremely positive feedback<br />

from Werkö’s plumbing equipment<br />

customer, as it brought tool costs and<br />

cycle times back to previous levels.<br />

Werkö GmbH<br />

Founded in 1938 in the<br />

Thuringian town of Königsee,<br />

today Werkö GmbH is a leading<br />

provider of precision machining<br />

tools for metalworking applications<br />

(HSS, HSCO, Solid Carbide)<br />

and is increasingly developing<br />

customized solutions. With 76<br />

employees, the company is part<br />

of the global TDC Group, which<br />

has sites in China, Mexico, Brazil,<br />

the USA and elsewhere.<br />

www.werkoe.de<br />

8 no. 2, August <strong>2019</strong>

materials & tools<br />

Carbide inserts coated with BALINIT® HARD CARBON extend<br />

the service time and improve process reliability when machining<br />

non-ferrous metals; the coating is thin, smooth, and with a high<br />

hardness, making it ideal for the machining of brass and copper<br />

Rico Fritzsche (left) from Oerlikon Balzers and<br />

Vicente Madrid from Werkö<br />

“There’s no one-size-fits-all solution<br />

here - each need is different, and ultimately<br />

it’s small details that will determine<br />

performance”, says Edda<br />

Enders. But Werkö’s fi nan cial director<br />

feels the com pany is in a good position<br />

thanks to the expertise it has<br />

acquired, particu larly as its cus tomers’<br />

first copper machining projects are<br />

now up and running, and later in<br />

<strong>2019</strong> Werkö will move to a new site in<br />

nearby Ilmenau with almost double<br />

the existing production space. “We’re<br />

well-equipped to deal with this niche<br />

market as it grows”, says a confident<br />

Enders.<br />

information: www.oerlikon.com/balzers<br />

Perfect machining of lead-free brass with<br />


Thilo Horvatitsch is a<br />

freelance author and<br />

journalist for technical<br />

and business topics,<br />

with 25 years of<br />

experience based in<br />

Essenheim near<br />


materials & tools<br />

The revolution in cast iron turning<br />

New generation of coatings<br />

Austrian carbide and tool specialist Boehlerit<br />

has optimised the successful TERAspeed 2.0 coating<br />

for use in cast iron milling. And now cast iron<br />

turning applications are also set to benefit. A thorough<br />

analysis of the market situation and coating<br />

tests that were completed internally paved the<br />

way for a new generation of coatings. The new cast<br />

CVD coating makes the most of the advantages<br />

of its individual components.<br />

Alpha-aluminium oxide is separated by means of targeted<br />

process management. It works as a heat shield and protects<br />

the indexable insert from high temperatures. Underneath,<br />

a medium-temperature titanium-carbon nitride layer provides<br />

the required wear resistance. A thickness of 20 µm<br />

and the optimised roundings of the edges ensure a high<br />

level of edge stability and ideal cutting conditions.<br />

The current geometries of the casting programme are<br />

made with the latest generation of reference clamping systems.<br />

Compared to older systems, the increased rigidity<br />

and repetition accuracy makes for a reduction of the pressing<br />

gap, which in turn increases press quality (burr-free<br />

pressing). This has a positive influence on work flows further<br />

down the line and significantly improves productivity.<br />

BCK10T and BCK20T<br />

The new<br />

Boehlerit casting<br />

grades<br />

BCK10T and<br />

BCK20T offer<br />

top quality, excellent<br />

machining<br />

properties<br />

and optimal<br />

distribution of<br />

cutting forces.<br />

Quattrotec - intelligent turning applications<br />

with new EasySafe system<br />

Pentatec, the universal turning-drilling tool, already<br />

replaces up to five ISO tools and reduces machining times<br />

by up to 30 % as tool changing times and unnecessary tool<br />

movements are eliminated. The innovative, revolutionary<br />

Quattrotec tool system is the next step in this intelligent<br />

machining concept, and the new EasySafe fitting system<br />

with a notch constitutes yet another major advantage of<br />

this product.<br />

With the introduction of the new Quattrotec tool system,<br />

Austrian carbide and tool specialist Boehlerit makes<br />

it possible for users to drive down costs further in an even<br />

broader material<br />

range.<br />

Thanks to the<br />

special design<br />

of the base<br />

body, four machining<br />

operations<br />

- drilling<br />

into solid<br />

material (including<br />

off-center<br />

Quattrotec<br />

drilling), in-<br />

side turning, face cutting and longitudinal turning - may<br />

be performed with low vibrations and just one single tool.<br />

The EasySafe system is the uncontested highlight of the<br />

Quattrotec: A notch on the underside of the indexable insert<br />

ensures that it can be fitted into the seat speedily and<br />

100 % correctly. Easy to install, safe to use!<br />

In a tried-and-tested, highly diverse range of grades,<br />

Boehlerit combines substrates of different levels of hardness,<br />

with either a wear-resistant CVD coating or a universal,<br />

process-safe PVD coating. The Kapfenberg-based tool<br />

specialist uses different carbide substrates that are coordinated<br />

in such a way as to achieve optimised machining<br />

properties. The market launch at the EMO in Hanover already<br />

saw no less than six directly pressed grades, and two<br />

more ground varieties for non-ferrous metals will be added<br />

in the next development phase. This means that the optimal<br />

cutting material will be available for almost every application.<br />

The innovative Quattrotec tool programme reduces machining<br />

and tool changing times, saves tool places and<br />

makes it possible to drill flat-bottomed blind holes. At the<br />

same time, this highly stable tool system that was developed<br />

from scratch also offers improved process safety and<br />

increases efficiency and flexibility during application.<br />

BETAtec 90P Feed and DELTAtec 90P Feed:<br />

fine-tuning down to the smallest detail<br />

The BETAtec 90P Feed tools are the ultimate edge milling<br />

tools in the Boehlerit milling programme. The<br />

BETAtec 90P Feed is a truly multi-functional <strong>tooling</strong> system,<br />

thanks to the fact that the tool holders may also be<br />

used with indexable cutting inserts for high-performance<br />

cutting. This means a higher level of efficiency and flexibility<br />

for users, while reducing not only the costs of the<br />

tool holder, but also the associated warehousing costs.<br />

The innovative tool system DELTAtec 90P Feed allows for<br />

highest feed rates and may be used for both HFC and edge<br />

milling. The multi-functional <strong>tooling</strong> systems are available<br />

as face milling, end milling and screw-on cutters and, in<br />

combination with the right cutting material grade, may be<br />

used across the entire material group.<br />

10 no. 2, August <strong>2019</strong>

materials & tools<br />

Innovative cutting grades for a<br />

broad range of applications<br />

For the BETAtec 90P Feed tool system, Boehlerit has a<br />

wide range of cutting grades available. One highlight is<br />

the innovative Goldlox carbide layer (PVD AlTiN layer) for<br />

the milling of steel materials, offering a high level of wear<br />

resistance at high temperatures and an increased lifespan<br />

on a range of steels. This cutting grade is particularly suitable<br />

for high cutting speeds during dry or wet machining<br />

in stable conditions. For this tool system, the Goldlox layer<br />

is available in the grades BCP25M (multi-purpose grade for<br />

the milling of unalloyed, low-alloy and high-alloy steel),<br />

BCP35M (suitable for dry milling at low to medium cutting<br />

speeds in difficult conditions) and BCM40M (ideal for<br />

the milling of austenitic stainless steels and materials from<br />

the Duplex group with low to medium cutting speeds).<br />

These two cutting grades are used both on the indexable<br />

inserts for edge milling and on the indexable inserts for<br />

high-performance cutting. There is also the option of cutting<br />

grade BCK20M for the edge milling of cast iron materials.<br />

This grade is also suitable for steel machining and for<br />

cold-work steels harder than 54 HRC.<br />

In addition<br />

to the Goldlox<br />

carbide layer,<br />

the DELTAtec<br />

90P Feed tool<br />

system also<br />

comes with<br />

a TERAspeed<br />

2.0AlTiN layer,<br />

d e p o s i t e d<br />

by means of<br />

HR-CVD technology<br />

(HR =<br />

High Reac tiv i-<br />

BETAtec 90P Feed<br />

ty). The patented<br />

TERAspeed<br />

2.0 AITiN layer combines opposing properties such as<br />

toughness, outstanding layer hardness and wear resistance,<br />

thanks to its high aluminium content and novel<br />

nano structure. This innovative layer is used for hig<strong>hp</strong>erformance<br />

cutting in the grades BCP20M (for steel processing<br />

using higher cutting speeds in stable conditions),<br />

BCP30M (universal steel milling grade with a tough carbide<br />

substrate for a high level of process reliability across a<br />

broad range of steel materials), and BCK15M (for the processing<br />

of grey cast iron GJL, spheroidal graphite cast iron<br />

GJS, tempered cast iron and alloyed cast iron).<br />

Alternatively, there is the option of the BCK20M grade<br />

for cast iron machining using DELTAtec 90P Feed millers.<br />

It has a tough K20 substrate and a thick PVD coating and<br />

may be used either for high performance milling or edge<br />

milling.<br />

Precise edge and EFC milling with<br />

18 mm cutting edge length<br />

In 2018, Austrian carbide and tool specialist Boehlerit<br />

added a version for 18 mm cutting edge lengths to its range<br />

of multi-functional<br />

milling<br />

tools. Thanks<br />

to the significantly<br />

larger insert<br />

size, this<br />

version is particularly<br />

suitable<br />

for long<br />

90-degree edges<br />

with high cutting<br />

values and<br />

an extremely<br />

DELTAtec 90P Feed<br />

high precision<br />

level. It not only makes for a soft cut, but also comes with<br />

tech nical properties that speak for themselves: A maximum<br />

cutting depth of up to 18 mm, in combination with<br />

a helix cutting edge, result in maximised productivity<br />

when finishing 90 ° shoulders with the BETAtec 90P Feed<br />

tool. For the high-feed application sector, the Boehlerit<br />

DELTAtec 90P Feed SD18 solution also offers the possibility<br />

of achieving maximum feed rates and high levels of material<br />

removal, with feed depths of 3.5 mm with a maximum<br />

feed rate of 3.0 mm/tooth.<br />

Small diameter range –<br />

highly dynamic and efficient<br />

Completely new, logical extensions of the existing<br />

BETAtec 90P Feed and DELTAtec 90P Feed portfolio are indexable<br />

inserts with small diameter ranges. The BETAtec<br />

90P Feed tool system with an indexable insert size of 06<br />

(LPMX06) is available as a face milling, end milling and<br />

screw-on version for a range of 10 - 50 mm. The DELTAtec<br />

90P milling tools are also available with an indexable insert<br />

size of 06 (SDMT06) as end milling and screw-on versions<br />

for a range of 16 - 35 mm.<br />

The new tools are ideal for die and mould making with<br />

materials of up to 62 HRC and extremely dynamic in terms<br />

of performance as well as efficiency. For applications with<br />

hardened materials, Boehlerit once again relies on a homogeneous<br />

HIPIMS layer structure for optimised results in die<br />

and mould making.<br />

Yet another benefit of this product lies in the low strain<br />

placed on the individual indexable inserts thanks to the<br />

narrow pitch that makes high machining volumes possible.<br />

The need for reworking is also greatly reduced due to the<br />

minimal need for residual material. While the BETAtec<br />

90P Feed is designed for HFC and 90 ° milling, the focus<br />

of the DELTAtec 90P Feed lies on material removal, with a<br />

focus on dynamic and efficient performance.<br />

EMO <strong>2019</strong>, hall 4, booth D06<br />

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

no. 2, August <strong>2019</strong><br />


materials & tools<br />

Efficient machining of aluminium<br />

The trend in milling is towards<br />

PCD monoblock<br />

LACH DIAMANT, the diamond tool manufacturer<br />

from Hanau, Germany, is well prepared for<br />

this topic. LACH DIAMANT is the only manufacturer<br />

with 40 years of know-how in producing<br />

PCD monoblock tools for serial production.<br />


PCD drill for<br />

machining of<br />

green carbide/ceramics<br />

Using monoblock milling purposefully<br />

means to profi tably “do<br />

without” the time-intensive setting<br />

of blades - pre-setting time -<br />

when using cassette cutters!<br />

Monoblock tools, e. g. “dia-compact”<br />

by LACH DIAMANT, are de -<br />

li vered as “plug & play“ and are immediately<br />

ready for use. The mono<br />

block PCD tool suite of LACH<br />

DIAMANT at EMO features PCD<br />

cutters from Ø 16 to 250 mm. Traditionally<br />

proven monoblock cutters<br />

like “dia-compact” are recommended<br />

for HCS/HPC alumi nium<br />

machining. In addition to the aluminium<br />

milling pro gramme, information<br />

for successful and costcutting<br />

machining of composite<br />

materials is being made available.<br />

PCD diamond drill<br />

Developed by the<br />

Hanau diamond tool<br />

manufacturer, the<br />

long-term tested spiral<br />

PCD diamond drills<br />

meet highest demands<br />

for the machining<br />

of green carbide and<br />

green ceramics:<br />

● for perfect drillin<br />

exit quality<br />

● superior tool times<br />

compared to coated<br />

carbide drills<br />

● re-grindable from<br />

Ø 2.5 mm<br />

Furthermore, LACH DIAMANT provides a large selection<br />

of spiral PCD drills up to 12 mm Ø for fine machining of<br />

composite (CFRP and GRP) and graphite components.<br />

EMO <strong>2019</strong>, hall 4, booth D40<br />

LACH DIAMANT monoblock<br />

cutters “dia-compact” are ready<br />

for use thanks to<br />

plug & play technology<br />

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

IGUANA - Evolution 2.0 - helical fluting included<br />

ZECHA has been manufacturing micro precision<br />

tools for 55 years now and has many years of<br />

experience in hard machining and diamond coating.<br />

And this is the ideal starting point for making<br />

innovative tools that employ existing knowhow<br />

and cutting-edge coating technologies.<br />

The machining of non-ferrous metals such as copper or<br />

high performance copper alloys and delicate contours and<br />

superb surfaces requires tried-and-tested tools such as the<br />

high-end IGUANA mill cutters from ZECHA Hartmetall-<br />

Werkzeugfabrikation GmbH from Königsbach-Stein. These<br />

solid carbide tools with high wear resistance, sealed diamond<br />

coating and laser-cut, sharp cutting edges master<br />

the challenge with gusto. The latest developments in the<br />

IGUANA tool family are two helical fluted lines: the 930<br />

milling cutter series and the 975 twist drill series.<br />

Optimisation of the laser process has enabled ZECHA to<br />

manufacture the IGUANA series with integrated helix. The<br />

almost freely selectable helical fluting of the tools promi ses<br />

great improvements in further areas of use. Materials diffi-<br />

cult to machine such as medical (fibre-reinforced) plastics<br />

or lead-free brass alloys can be ideally machined thanks<br />

to the positive helical characteristics - softer cut, rounded<br />

groove forms, improved chip removal etc.<br />

The new helical fluted milling cutters are available as<br />

dual flute ball or torus milling cutters in diameters ranging<br />

from 0.5 mm to 3 mm. In addition, ZECHA also offers<br />

a triple-fluted shaft milling cutter in diameters of 1 mm to<br />

6 mm. All three versions in the 930 series are suitable both<br />

for wet and dry machining. The uniform geometric conditions<br />

across the entire cutting edge length produces an<br />

even softer, burr freer cut and the optimum chambers ensure<br />

excellent chip removal and machining results.<br />

Innovation - IGUANA drills<br />

Apart from the new helical fluted high end IGUANA<br />

milling cutters, ZECHA has also introduced a solid carbide<br />

micro twist drill with diamond coating and lasersharpened<br />

cutting edges to its tool range. The IGUANA<br />

twist drills have a digressive helix with right-hand cutting<br />

direction and are self-centring due to the X drill point<br />

12 no. 2, August <strong>2019</strong>

materials & tools<br />

IGUANA milling cutters and drills with<br />

helical fluting (series 930 and 975)<br />

located on the drill head. These drills, just like the<br />

IGUANA milling cutters, have been furnished with a laser-machined,<br />

sealed high performance diamond coating<br />

with edge protection and are available in diameters ranging<br />

from 0.8 mm to 2.0 mm.<br />

IGUANA - laser-processed tools with integrated helix<br />

Conclusion:<br />

The high-end IGUANA series efficiently masters the typically<br />

encountered challenges such as pre ci sion, tool life<br />

and manual reworking. The line increases productivity, as<br />

it results in less tool changeover and thus also lower downtimes.<br />

IGUANA tools machine to a very good geometric accuracy<br />

and produce virtually no burring, which is great<br />

advantage as regards process capability. Never the less, it is<br />

always true to say that only the perfect interplay of man,<br />

machine and tool can achieve a perfect result.<br />

further information: www.zecha.de

materials & tools<br />

Significantly better surface finishes<br />

thanks to vibration damping<br />

Vibration often occur during machining. This<br />

leads to dynamic instability of the system. Inadequate<br />

surface finishes, insufficient accuracy, high<br />

machining noises, shortened tool lives and, in extreme<br />

cases, broken tools and cutting edges can be<br />

the result.<br />

In order to minimise these vibrations and their consequences,<br />

MAPAL has now developed an innovative system<br />

for vibration damping in the tool shank, as particularly<br />

tools for boring and milling with very long projection<br />

length tend to vibrate due to an inadequate dynamic<br />

rigidity of the overall system. When designing the new<br />

system, the developers took into account all factors arising<br />

from the interaction of the machine tool, the tool and<br />

type of clamping as well as the component. The result: A<br />

system for vibration damping that is matched to all common<br />

types of machine stiffness. It can be used for machining<br />

different materials with different tools.<br />

The self-contained system of auxiliary mass and several<br />

steel spring packages counteracts the deflection of the tool<br />

body and minimises it. The vibrations can be up to 1,000<br />

times lower compared to tools without absorber system.<br />

Despite the long projection length, quiet,<br />

stable running is achieved. This makes<br />

it possible to work at higher cutting<br />

speeds and significantly increases<br />

the material<br />

removal rate.<br />

Vibration<br />

damping is integrated<br />

directly into the tool shank<br />

of the new milling cutter arbor<br />


vibration damper<br />

In addition, significantly better surface finishes are<br />

achieved thanks to vibration damping. When milling case<br />

hardened steel (16MnCr5), for example with a 250 mm<br />

long combination of milling cutter arbor and milling<br />

cutter with five cutting edges and ISO indexable inserts<br />

(Ø 50 mm), the Rz value was halved from 7.8 µm to 3.9 µm<br />

for material removal ae of 18 mm and ap of 3 mm compared<br />

to the same tool system without vibration damping.<br />

Milling cutter arbors with vibration damping in the<br />

shank are available with internal coolant supply for clamping<br />

Ø 16, 22 and 27 mm with a length of 200 and 300 mm<br />

for SK40, SK50, HSK-A63 and HSK-A100 connections.<br />

EMO <strong>2019</strong>, hall 4, booth A18<br />

WITH<br />

vibration damper<br />

Thanks to the new milling cutter arbors with vibration damping,<br />

significantly better surface finishes are achieved during machining;<br />

for comparison: The left milling paths were machined without<br />

vibration damping and the right one with vibration damping<br />

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

Team Cutting Tools from CERATIZIT<br />

A complete provider of machining solutions<br />

With the world-leading flagship brands of Cutting<br />

Solutions by CERATIZIT, KOMET, WNT and<br />

KLENK making up Team Cutting Tools, the machining<br />

sector has a genuine complete provider in<br />

the shape of the CERATIZIT Group.<br />

These famous names, which are known all over the<br />

world, focus on what they do best, this being indexable indexable<br />

insert tools, hole production, solid carbide and HSS<br />

rotating tools, tool/workholding, and aerospace applications,<br />

respectively. These highly specialised product brands<br />

FreeTurn tool<br />

14 no. 2, August <strong>2019</strong>

materials & tools<br />

provide access to the best <strong>tooling</strong> systems<br />

available; Team Cutting Tools is<br />

able to deliver the perfect solution for<br />

every machining requirement. These<br />

machining solutions, over 100,000<br />

items, can be found in the new complete<br />

catalogue, which was published<br />

in July. Users can also visit the new<br />

online shop at cuttingtools.ceratizit.com<br />

to view the full range and access the<br />

complete programme.<br />

Expert solutions for sectors<br />

Besides having one of the most com -<br />

prehensive standard portfolios, Team<br />

Cutting Tools also offers sector-specific<br />

solutions. Visitors to EMO can ex pe rience<br />

its sector expertise first-hand. Interactive<br />

presentation spaces are the<br />

per fect platform for showing off core<br />

skills in the automotive, aerospace,<br />

energy technology and heavy machin<br />

ing sectors. One of the highlights<br />

making its world première at the fair:<br />

additive manufacturing tools for the<br />

machining of E-motors.<br />

Experience Industry 4.0 solutions<br />

CERATIZIT sets course for the digital<br />

machining future. A central aspect<br />

of this is the ToolScope monitoring<br />

and assistance system. The system<br />

permanently stores the signals that<br />

are generated by the machine during<br />

the manufacturing process. This information<br />

is visualised and used to<br />

monitor and supervise the machine<br />

controller. Special, patented statistical<br />

control processes are then employed<br />

to depict the condition of the<br />

tool and the machine. This not only<br />

enables targeted wear and fracture<br />

monitoring to be carried out, it also<br />

greatly reduces manufacturing errors.<br />

Visitors to the innovation center on<br />

the stand will also discover the potential<br />

offered by the sensory “spike”<br />

tool holder from pro-micron and how<br />

One Identity can be used to clearly<br />

identify tools.<br />

Impressive service<br />

In addition to tool systems, digitisation<br />

solutions and innovations,<br />

CERATIZIT will also present its service<br />

offering, which plays a key role<br />

within the company. From project design<br />

for customers to technical training<br />

and the 24/7 supply of tools,<br />

CERATIZIT offers many additional<br />

services that companies in the metalworking<br />

and processing industries can<br />

find out about on the stand.<br />

EMO <strong>2019</strong>, hall 5, booth B70<br />

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

No exhibition without innovations.<br />

The High Dynamic Turning and Free-<br />

Turn tools from CERATIZIT have alrea<br />

dy won several international<br />

awards and will undoubtedly be<br />

a mong the con tenders for the most<br />

in no vative products at EMO. The new<br />

tur n ing technology offers huge potential<br />

for machining companies. With<br />

the help of the milling spindle on a<br />

multi-tasking turn/mill center, the<br />

360 ° rotation clearance angle allows<br />

the tool to be positioned at any angle<br />

relative to the workpiece. Among the<br />

many advantages are higher feedrates<br />

and a longer service life, together with<br />

shorter tool changing times and fewer<br />

tools. All of which sounds fine in theory,<br />

but does it actually work in practice?<br />

Team Cutting Tools will provide<br />

the answer with a live demonstration on<br />

a turn-mill center on the CERATIZIT<br />

stand. EMO will also see the unveiling<br />

of the first standard range of Free-<br />

Turn tools.<br />

Hall 6 | Stand K67<br />

NOVAMET 920<br />


Efficient<br />

excellent run-off<br />

Clean<br />

high flushing performance<br />

Safe<br />

boron- and biocide-free<br />

Oemeta Chemische Werke GmbH | Phone: +49 (0) 4122-924-0 | products@oemeta.com<br />


materials & tools<br />

Compression Routers in woodworking<br />

offer a superior cut<br />

Reducing waste and improve cutting finish<br />

Simon Richardson ANCA<br />

Product Manager gives some insight<br />

into the use and applications<br />

for solid carbide Compression<br />

Routers (also known as<br />

compound shear cutters) used in<br />

the woodworking industry.<br />

Compression Routers (CR) are used<br />

for machining composite materials<br />

and extensively in the woodworking<br />

industry to cut solid wood and particle<br />

boards. CR for woodworking applications<br />

are distinct from other types<br />

of shank tools as they have opposing<br />

flutes and can have both right and<br />

left helix cutting edges. Available in<br />

roughing (with chip breakers) and for<br />

finishing operations CRs are also produced<br />

in a range of single flute and<br />

multiple flute tools.<br />

ANCA’s ToolRoom Software has<br />

a dedicated package to produce all<br />

types of Compression Routers with<br />

the required geometry. In addition,<br />

the digitising routines within the<br />

software exactly follow the geometry<br />

which means regrinding Compression<br />

Routers is easy.<br />

Benefits of<br />

Compression Routers<br />

Compression Routers are used for<br />

machining wood, flat pack furniture,<br />

kitchen cabinets and worktops. Materials<br />

such as plywood and melamine<br />

board have a finished face on the top<br />

and bottom of the material. When the<br />

board is cut “break out” or chipping<br />

of the material on either side of the<br />

board can occur and looks unsightly.<br />

Severe break out or chipping after cutting<br />

can mean the part is scrapped or<br />

further finishing or sanding work is<br />

required.<br />

Simon Richardson says the benefit<br />

of a Compression Router is when<br />

it cuts the material the tool “compresses”<br />

the chips towards the center<br />

of the tool. The “upcut” part of the<br />

router forces chips upwards while the<br />

“downcut” section forces chips downwards<br />

towards the tip of the tool.<br />

Cutting tool manufacturers know<br />

when grinding a CR, it can be a challenge<br />

to maintain size consistently<br />

between the up and down cut diameters.<br />

For these types of tools fluting<br />

can be a contributor to diameter<br />

variance. ANCA’s LaserPlus system<br />

supports measurement and compensation<br />

of Compression Routers. It is<br />

now possible to measure both up and<br />

down cut diameters or single sections<br />

of the router using the laser. This capability<br />

is invaluable for companies<br />

producing these tools as consistency<br />

will be maintained between the cutting<br />

diameters.<br />

CR are used on CNC Gantry Routers<br />

or five- to three-axis machining centers<br />

for cutting many sheets of board<br />

at the same time or multiple profiles<br />

from one sheet (called nesting). CR<br />

can cut boards to size, outer edges,<br />

profile slots and drill holes through<br />

the skin of the material. When using<br />

a CNC router or machining center, a<br />

16 no. 2, August <strong>2019</strong>

materials & tools<br />

suction bed is required to rigidly hold<br />

the material (some machines have<br />

physical clamps). Suction beds have<br />

pods for raising the work above the table<br />

for edge profiling or undercutting.<br />

Dust extraction and collection is<br />

critical to ensure ade quate chip removal<br />

to carry the chips away from<br />

the work piece. Feeds and speeds<br />

can be adjusted to increase the chip<br />

load and take heat away from the<br />

cutter, but the dust collection system<br />

must be powerful enough to remove<br />

chips from the work area.<br />

Good housekeeping will also mean<br />

that collets, collet nuts and spindles<br />

should be continually maintained<br />

as dust build up will affect<br />

performance.<br />

Compression Router geometry<br />

Helix angles required for woodworking<br />

are considered low when compared<br />

to metal cutting tools. A helix<br />

angle range between 22 ° to 30 ° would<br />

be considered in many wood applications.<br />

But clearance angles used are<br />

a lot higher with materials such as<br />

Medium Fibre Density (MDF) board<br />

due to “spring back” after separation<br />

from the chip. This “spring back” of<br />

the material is why multiple OD back<br />

offs are used on a CR and clearance<br />

angles between 15 - 20 ° are standard.<br />

As a rule, when machining softer<br />

materials larger rake angles can be<br />

used. Particularly when cutting wood<br />

and MDF, a larger rake angle will lift<br />

fibres rather than flatten them. When<br />

machining wood materials, insufficient<br />

clearance angles, with smaller<br />

hook angles can have the following<br />

negative effects:<br />

● increased tool wear<br />

● raised or fuzzy grain<br />

● burning or glazing of the material<br />

In addition to the tool geometry,<br />

the operator must also consider the<br />

following:<br />

● grain directions in the material<br />

● spring back of the material during<br />

the cut<br />

● the wear rate of the cutting edge<br />

and how it reacts to the material<br />

being cut<br />

● resins in hard and softwoods<br />

● glues included in the sandwich<br />

materials such as plywood<br />

● contaminates included in<br />

materials like chipboard<br />

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

16. - 21.<br />

September<br />

<strong>2019</strong><br />

Hall 4,<br />

Booth D06<br />

Quattrotec –<br />

Intelligent turningdrilling<br />

applications<br />

with EasySafe system<br />

■ Drilling into solid material with flat drilling<br />

base (including off-centre drilling), inside<br />

turning, face cutting and longitudinal turning<br />

– performed with low vibrations and<br />

just a single tool<br />

■ EasySafe System – A notch on the under<br />

side of the indexable insert ensures that it<br />

can be fitted into the seat speedily and<br />

100 % correctly<br />

■ Optimal cutting material will be available for<br />

almost every application<br />

■ Reduces machining and tool changing times<br />


materials & tools<br />

LACH DIAMANT looks back on 95 years - second part<br />

Poly - poly - or what?<br />

How the story continued<br />

Horst Lach, managing director<br />

and CEO of LACH DIAMANT<br />

agreed to write an ongoing series<br />

of articles about the development<br />

of diamond and CBN tools<br />

and grinding wheels in modern<br />

industries. The occasion: LACH<br />

DIAMANT’s 97th anniversary in<br />

the run up to EMO.<br />

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

veteran, and we are ex cited<br />

to have this pioneer of techno -<br />

logy share some insights from 59<br />

years of professional experience<br />

in the diamond tool business.<br />

In this part of this (almost) historical<br />

review, Horst Lach looks<br />

back to the first twelve months<br />

after introducing the first polycrystalline<br />

machining tools.<br />

Where do we come from - what is<br />

our destination? This was the question<br />

after the first introduction of this<br />

new cutting material “polycrystalline<br />

diamonds” (PCD) at the Hanover Trade<br />

Show in 1973.<br />

Despite the word “poly”, the basis<br />

here is “diamond” (Greek: Adamas),<br />

naturally created from carbon in the<br />

depths of the earth under heat and<br />

pressure over millions of years. Diamond<br />

in its monocrystalline form is<br />

still the hardest of all things.<br />

Even before people discovered its<br />

beauty - “diamonds are a girl’s best<br />

friend” - they made use of the hardness<br />

of this “indomitable” material in<br />

the earliest archaeological sites in India,<br />

e.g. for the turning and levelling<br />

of mill stones.<br />

Tracy Hall and his first diamond press;<br />

source «Higher Learning»,<br />

edition July 2014<br />

The industrial revolution, starting<br />

in England around 1770, and its<br />

powerful continuation in Germany<br />

in the mid 19th century would not<br />

have been possible without diamonds.<br />

They were instrumental especially for<br />

the production of steam engines and<br />

locomotives. More precise grinding<br />

machines, studded with wheels for<br />

steel grinding, had to be developed,<br />

and without diamond dressing tools,<br />

only geometrically distorted surfaces<br />

would have resulted. The demand for<br />

natural diamonds from Brazil and<br />

Africa skyrocketed during the following<br />

100 years - and gained strategic<br />

importance due to both world wars.<br />

There was an increased need and desire<br />

to grow diamonds or to produce<br />

synthetic diamonds in order to become<br />

less dependent on the commodity<br />

markets in London and Antwerp.<br />

The engineer who<br />

implemented ideas<br />

So it is no wonder that in 1954 engineer<br />

Tracy Hall was the first who succeeded<br />

in growing synthetic “manmade”<br />

diamonds in the United States,<br />

using a specially developed high-pressure<br />

press. When General Electric first<br />

marketed these synthetic granulated<br />

diamonds, with sizes of approximately<br />

170 microns, under the brand name<br />

“Man Made Diamond” in 1957, it was<br />

one more step towards another technical<br />

revolution, which, to this day, is<br />

affirmed through new innovations.<br />

Milling with PCD - introduced for the first time on a Hermle milling machine with<br />

triple-studded cutter head during Hanover Trade Show 1974<br />

Once again, it was Tracy Hall who -<br />

in 1967/68 - implemented the idea to<br />

bake very fine diamond grains with<br />

18 no. 2, August <strong>2019</strong>

materials & tools<br />

car bide as a carrier material during<br />

syn thesis. He was successful: The first<br />

step towards a so-called polycrystalline<br />

synthetic diamond cutting material<br />

had been accomplished. EDG (Electrical<br />

Discharge Grinding for dividing the<br />

round plates which at first had a diameter<br />

of approximately 3.2 mm) had<br />

not yet been discovered. Therefore,<br />

the carbide had to be scored with electro-plated<br />

diamond cutting discs in<br />

order to be able to break off either 90<br />

or 60 degree segments afterwards.<br />

A new cutting material &<br />

the first users<br />

What to do with this new innovation?<br />

General Electric’s management<br />

must have been faced with the same<br />

question at that time. After all, in<br />

1966/67 the key “monopoly players”<br />

General Electric and DeBeers had introduced<br />

metal-coated diamond granulation<br />

and achieved super adhesive<br />

strength in resin-bond grinding wheels, which in turn<br />

made the use of carbide tools efficient for the industry for<br />

Crude composite cutting inserts;<br />

source «Bericht schnelleres Drehen, Bohren und Fräsen…»,<br />

Horst Lach MM issue 11/1973<br />

the first time. It was said that General Electric had good<br />

reason to protect its own carbide business within the corporate<br />

group - referring to its subsidiary “Carboloy”.<br />

Nevertheless, the up-and-coming managers under<br />

the leadership of Louis Kapernaros must have prevailed<br />

within the big GE family. It was de cided to provide samples<br />

of the new cutting material to three or four selected<br />

diamond companies, including LACH DIAMANT. Appar -<br />

ently, GE was curious to see whether the company - known<br />

as “Borazon Pioneer” since the introduction of the CBN<br />

grinding wheel in 1969 - would once again come up with a<br />

lot of new ideas.<br />

It was in the spring of 1974, shortly before the<br />

Hanover Trade Show, the second year after the first PCD<br />

presentation. Since the introduction of PCD for manufacturing<br />

copper commutators, we had practiced PCD turning<br />

instead of grinding and had tried to win new customers<br />

among alumi nium processing companies such as<br />

Westinghouse, Voith, Solex and Oechsle, an enthusiastic<br />

PCD cus tomer - which is still surprising to me today. The<br />

company worked with polyamide synthetic materials, and<br />

produced small gears with imprinted numbers for the production<br />

of vehicle odometers.<br />

Looking back, many new and unusual applications were<br />

added within a short period of time, e.g. the Dutch manufacturer<br />

for Meerschaum pipes who could now produce the<br />

mout<strong>hp</strong>iece faster and more precisely. As a thank you, he<br />

brought his latest pipe selection to each trade show for several<br />

years - which was a special delight to our sales manager,<br />

engineer Günter Hobohm, a passionate pipe smoker.<br />

LACH Precision Toll Grinder for single tipped PCD-Tools –<br />

developed 1973 in license company Kelch<br />

The automobile industry, later the main user of this new<br />

technology, was not one of the first users. An attempt of<br />

a North German diamond tool ma nu facturer to replace<br />

no. 2, August <strong>2019</strong><br />


materials & tools<br />

natural diamonds in the turning process of motor pistons<br />

could not be successful at this time. The poly cutting edge<br />

was considered to be too rough due to its poly saw character.<br />

This only changed many years later when it was discovered<br />

that its “roughness” would be perfectly complimentary<br />

to an elastic film of lubricant; broken down cars<br />

with seized pistons would be seen as a distant memory.<br />

This new business segment which had been growing<br />

rapidly within only a few months, also influenced<br />

the strategic planning at LACH DIAMANT. A newly finished<br />

industrial building, initially meant for the similarly<br />

booming branch of diamond and Borazon CBN grinding<br />

wheels, was turned into the first production facility<br />

for PCD tools. From now on, LACH DIAMANT PCD tools<br />

were marketed under the registered name dreborid®.<br />

Internal turning with PCD tools –<br />

current development status in 1973/74<br />

Thereby, we were perfectly prepared for the manufacturing<br />

of so-called “single-tipped” tools for the trade show<br />

in 1974.<br />

What kind of innovations did LACH DIAMANT deliver<br />

for the future use of PCD tools? One example was PCDtipped<br />

carbide according to ISO. After discovering the fact<br />

that PCD cutting edges could be re-ground multiple times,<br />

customers wanted to continue to use carbide clamping devices<br />

for cutting inserts - for turning and milling! Milling?<br />

Another application. PCD milling was born.<br />

First PCD cutting inserts<br />

made in 1973/74<br />

At that time, the grinding wheel production moved into<br />

a neighbour building, a large facility which happened<br />

to become vacant, and stayed there until 1984 when we<br />

moved to Donaustrasse in Hanau.<br />

PCD milling as new technology<br />

Rapid growth - combined with the demand for shorter<br />

delivery times - forced us to find better conditions for<br />

grinding this “beastly material” (as our former Master diamond<br />

grinder Konrad Wagner dubbed it at that time).<br />

After a search for a suitable machine, we finally found it<br />

at the Kelch company. In the following years, this machine<br />

was further adjusted to the particularities of PCD grinding.<br />

After taking over the license and construction, LACH<br />

DIAMANT is still building this machine, referred to as<br />

“pcd-100/300”.<br />

The patent issue<br />

The highlight at our trade show stand in 1974 was therefore<br />

PCD inserts for turning and milling. PCD milling was<br />

demonstrated as a new technology on a Hermle milling<br />

machine with 5.000 rpm - equipped with a triple-studded<br />

cutting head. Alu minium and Duroplast parts as well as<br />

composite materials were milled.<br />

At that time, interest could be called “enormous” - it was<br />

simply a success. At least until the alarmed junior manager<br />

of a North German company (back then considered an industry<br />

leader) appeared at our stand and asked reproachfully<br />

why LACH DIAMANT dared to show PCD tools for<br />

milling. His company had applied for the patent for this<br />

technology. At least two licenses had already been won<br />

in the Württemberg area. Well, in the end, the discussions<br />

at the trade show resulted in a free license for LACH<br />

DIAMANT. And as the reader might has already guessed,<br />

the patent came to nothing.<br />

It is only mentioned in passing that another technologically<br />

sound idea was born during those days - reaming<br />

with PCD, an application we then discussed with a young<br />

man from Swabia for a potential cooperation.<br />

Horst Lach<br />

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

20 no. 2, August <strong>2019</strong>

The Art of Grinding.<br />

A member of the UNITED GRINDING Group<br />

S31<br />

The versatile solution for large tasks.<br />

EMO<br />

HANNOVER <strong>2019</strong><br />

16 – 21<br />


Hall 11, Booth B24<br />

Are your grinding tasks complex and<br />

diverse? Then we recommend the S31.<br />

This is the system for small to large<br />

workpieces. With a high-resolution B-axis<br />

of 0.00005°, the flexible wheelhead enables<br />

external, internal, and surface grinding in<br />

a single clamping. Try out the revolutionary<br />

StuderGuide ® guideway system with its<br />

cushioning components in the direction of<br />

motion.<br />

www.studer.com – The Art of Grinding.

materials & tools<br />

New Leitz DT Premium compact hogger<br />

20 % less panel processing costs<br />

At LIGNA, the world’s leading trade fair for<br />

machinery, plant and tools for the woodworking<br />

and timber processing industry, Leitz presented its<br />

new diamond tipped DT Premium compact hogger<br />

with optimized cutting geometry, improved<br />

chip removal and additional damping elements.<br />

The precision tool manufacturer from Oberkochen<br />

is thus replacing its proven DT PLUS product and<br />

enabling users in the furniture industry to achieve<br />

significant increases in productivity and efficiency.<br />

Individual customer requirements, the increasing variety<br />

of decors and the increasing proportion of waste wood<br />

in the panel material confront manufacturing companies<br />

with new challenges every day. The associated numerous<br />

tool changes, downtimes, frequent material changes and<br />

fast wearing tools make it difficult for manufacturing companies<br />

to keep processing costs low, but at the same time<br />

to keep output and quality constantly high.<br />

The new DT Premium compact hogger from Leitz offers<br />

protection in such scenarios. Compared to the previous<br />

model DT PLUS, the advantages of the further development<br />

DT Premium are obvious. With a significantly longer<br />

life time, impressive results were achieved in the long-term<br />

test at various Leitz customers in terms of productivity<br />

and effectivity.<br />

Leitz compact hogger DT Premium -<br />

excellent edge quality and smooth cutting surface by<br />

adjusted cutting edge geometry (photo: Leitz)<br />

Equally important, the long life time also has an effect<br />

on the efficiency of the tool. Fewer tool changes and<br />

downtime in series productions as well as the permanent<br />

usability in batch size 1 production makes it possible to reduce<br />

machining costs by up to 20 %. The constant cutting<br />

width after sharpening, the perfect edges and smooth cutting<br />

surfaces are further quality features that prove that<br />

the new DT Premium compact hogger offers a convincing<br />

price-performance ratio.<br />

The new compact hogger is also convincing from the<br />

point of view of sustainability. The resharpenability has<br />

been significantly increased to 15 sharpening cycles and<br />

the specially developed tool design reduces annoying<br />

noise and avoids vibrations.<br />

Leitz compact hogger DT Premium –<br />

maximum efficiency due to long life time (photo: Leitz)<br />

Productivity, efficiency, quality and sustainability describe<br />

this new generation of Leitz compact hoggers in<br />

brief. With this efficient and highly economic new development,<br />

Leitz once again emphasizes its technological<br />

leadership and sets a clear sign for customer and marketoriented<br />

product development which takes into account<br />

the trends of the industry and at the same time always focuses<br />

at the advantage of the customer and user.<br />

further information: www.leitz.org<br />

22 no. 2, August <strong>2019</strong>

materials & tools<br />

Milling instead of polishing<br />

Paul Horn GmbH is expanding its tool range<br />

for brilliant-finish milling. The monocrystalline<br />

diamond-tipped (MCD) ball nose end mills are<br />

intended for machining non-ferrous materials in<br />

the tool and mould making industries.<br />

Milling with MCD-tipped tools saves on polishing processes<br />

when producing freeform surfaces. The new, larger<br />

diameter variants reduce machi ning time, guarantee compliance<br />

with the tightest tolerances and produce surface<br />

finishes in the nanometre range.<br />

Horn offers the expanded portfolio of MCD ball nose<br />

end mills from stock. Diameters of 6 mm, 8 mm, 10 mm,<br />

12 mm and 16 mm allow a broader range of applications to<br />

be covered. All variants are single-edged and feature an internal<br />

coolant supply. The solid carbide tool shanks enable<br />

vibration- and oscillation-free machining.<br />

quality. Financial savings are achieved due to the possibility<br />

of retipping, lower tool costs and reduced machine<br />

downtime. The internal coolant supply to both cutting<br />

edges via the round shank cools the contact zone and carries<br />

the chips away efficiently.<br />

Horn offers the tools in profile widths (w) of 16 mm,<br />

20 mm and 26 mm. Special profiles are precision ground<br />

to suit the application. The maximum profile depth is<br />

tmax = 17 mm. The maximum profile width is w = 26 mm.<br />

The insert coating is specially selected for each application<br />

and is available for material groups P, M, K and N. The<br />

round shanks are available as standard with diameters of<br />

16 mm, 20 mm and 25 mm in the A and E designs. All variants<br />

have an internal coolant supply.<br />

Using MCD tools, laborious polishing<br />

processes are no longer needed<br />

Horn offers customised form inserts based on the 117 tool system<br />

for use on turning and mill-turn centers<br />

The range of applications for brilliant-finish milling is<br />

huge. In the tool and mould making industry in particular,<br />

the method saves on polishing, while also increasing quality<br />

in terms of precision, contour accuracy, flatness and<br />

surface finish. It is therefore used in applications where the<br />

surface qua lity of the mould needs to be matched by the<br />

finish of the parts being produced. For example, they include<br />

PET blow moulds and chocolate moulds as well as<br />

applications in the medical technology sector. In addition<br />

to brilliant-finish milling, Horn also offers solutions for<br />

brilliant-finish turning with MCD tools.<br />

Economic advantages<br />

in series production<br />

Turning with form tools allows customers to benefit<br />

from economic advantages in series production. Horn offers<br />

customised carbide form inserts based on the 117 tool<br />

system for machining diameters from 16 mm upwards on<br />

turning and mill-turn centers. The patented, precision insert<br />

seat of the 117 system guarantees high concentricity<br />

and minimal axial run out as well as high repeatability of<br />

insert exchange to within microns. The precision-ground<br />

cutting edges achieve a high level of accuracy and surface<br />

The DDHM system<br />

Horn presents DDHM, its CVD diamond-tipped tool<br />

system for cost-effective drilling and countersinking of<br />

sintered carbides and ceramics with a hardness of up to<br />

3,000 HV. With the launch of this drilling and milling system,<br />

Horn is further expanding its range of products for<br />

machining fully sintered carbides. As they allow machining<br />

to take place on conventional milling or turning centers,<br />

these tools do away with costly and time-consuming<br />

grinding and eroding processes. There is also an opportunity<br />

for savings, as investment in expensive new machinery<br />

can potentially be avoided. The DDHM system is particularly<br />

aimed at customers in the tool and die making<br />

sector owing to its ability to machine carbide punches and<br />

dies efficiently.<br />

The drills can be used for producing holes in solid material<br />

to a maximum depth of ten times the diameter.<br />

The CVD-D-tipped drills have a two-edged design and<br />

are available in diameters ranging from 2 mm (0.079”) to<br />

10 mm (0.394”). All versions feature an internal coolant<br />

supply.<br />

EMO <strong>2019</strong>, hall 5, booth A54<br />

further information: www.phorn.de<br />

no. 2, August <strong>2019</strong><br />


materials & tools<br />

WJX - high feed milling cutters<br />

Mitsubishi Materials has<br />

added a series of high feed cutters<br />

to its comprehensive range<br />

of indexable milling tools. WJX<br />

has been designed to be multifunctional<br />

and able to perform<br />

at high feed rates to ensure usability<br />

and efficiency across a<br />

wide choice of applications.<br />

The high feed capability of this new<br />

cutter means it is ideal for rough machining<br />

under the demands of modern<br />

high efficiency conditions. WJX<br />

achieves stable machining and lowers<br />

cutting noise at high depths of cut<br />

and even during interrupted machining.<br />

This is due to its ability to reduce<br />

the cutting resistance generated at the<br />

initial point of contact between the<br />

insert and material.<br />

VQT6 end mill_end view<br />

Inserts<br />

The double-sided negative inserts<br />

with the complex-shaped flank face<br />

provides excellent economy, increased<br />

sharpness and strength. The unique<br />

cutting edge geometry forms short<br />

chips and helps to prevent chip tangling<br />

to further enhance usability. To<br />

cope with the loads at high feed rates,<br />

the increased insert thickness provides<br />

the strength needed and helps<br />

to prevent sudden fracturing. Further -<br />

more, a straight section of the cutting<br />

edge extends along the insert to<br />

enable high feed machining even at<br />

maximum depths of cut.<br />

vides stable clamping without the<br />

need to use a clamp bridge. In addition,<br />

the dovetail insert pocket geometry<br />

helps to absorb cutting forces.<br />

The cutting edge also has a small wiper<br />

face that provides good surface finishes<br />

for rough machining. Overall,<br />

the geometry of the inserts provides<br />

the best features of tradi tional single<br />

sided inserts, namely good ramping<br />

performance and sharpness, whilst<br />

also having the best double sided features<br />

of cost effi cien cy and strength.<br />

Grades and sizes<br />

Five different grades of insert with<br />

Mitsubishi’s latest generation of coatings<br />

are available to cover an extensive<br />

range of materials. This multiple<br />

choice of grades permits the high efficiency<br />

machining of steels and stainless,<br />

cast iron, heat resistant alloys,<br />

titanium and hardened steels<br />

The face mill type cutter bodies are<br />

available in Ø 63, 80, 100, 125 and<br />

160 mm. Whilst the shank type is<br />

available in Ø 42 mm.<br />

VQT6UR –<br />

new 6-flute conical taper<br />

barrel end mills<br />

VQ, the latest series of end mills<br />

from Mitsubishi Materials has been<br />

further expanded to include an innovative<br />

new 6-flute, conical taper barrel<br />

type. This latest addition has been<br />

specially designed for high efficiency<br />

finish machining of titanium alloy<br />

blades and for milling other materials<br />

from mild steel through to aluminium<br />

alloys<br />

The ability to outperform standard<br />

ball nose end mills is provided by the<br />

large conical taper barrel form that<br />

blends seamlessly with the nose radius.<br />

This larger tangential radius permits<br />

a much greater overlap (ap) and<br />

therefore greatly reduces the number<br />

of passes required to cover the surface<br />

area of the material being machined.<br />

The larger overlap also leads to significant<br />

improvements in the surface<br />

finish. Additionally, the 6-flute geometry<br />

permits greater feeds and<br />

promotes further savings in machining<br />

time.<br />

VQT6 with turbine<br />

When compared to ball nose end<br />

mills, the conical taper form with the<br />

much larger area of contact with the<br />

workpiece during barrel milling could<br />

lead to chatter and vibration, but this<br />

concern is negated by the irregular<br />

pitch geometry of the flutes. The radial<br />

accuracy of ± 0.01 mm for the end<br />

(RE1) and barrel radii (RE2) are also<br />

key factors in maintaining consistent<br />

geometrical accuracy of the finished<br />

component. Furthermore, the 6-flutes<br />

are reduced to 3-flutes to widen the<br />

area at the nose radius to promote improved<br />

chip evacuation. This end geometry<br />

is ideal for root form machining.<br />

Coating<br />

VQ solid carbide end mills have<br />

been treated with an innovative (Al,<br />

Cr) N group MIRACLE SIGMA based<br />

coating which delivers substantially<br />

improved wear resistance. The surface<br />

of the coating has been given a<br />

smoothening treatment resulting in<br />

better machined surfaces, reduced<br />

cutting resistance and an increased<br />

chip discharge capacity. The extreme<br />

heat and oxidation resistance and<br />

lower coefficient of friction of the new<br />

coating means this next generation of<br />

end mills can maximise performance<br />

and help prevent tool wear even<br />

under the harshest of cutting conditions<br />

when machining difficult to cut<br />

materials.,<br />

VQT6UR sizes<br />

Four sizes are available:<br />

Ø 8, two Ø 10’s and a Ø 12. They have<br />

an end radii (RE1) of 2 mm, 2 mm,<br />

3 mm and 4 mm respectively and a<br />

barrel radii (RE2) of 75 mm, 85 mm,<br />

75 mm and 100 mm respectively.<br />

The chip pocket area is left clear by<br />

use of a dovetail geometry that prevents<br />

the insert from lifting and proinformation:<br />

www.mmc-hardmetal.com<br />

24 no. 2, August <strong>2019</strong>

materials & tools<br />

NC Helix Drill performs<br />

multiple applications<br />

Less machining time and tool costs<br />

NC Helix Drill performs<br />

multiple applications as rough<br />

milling, slotting or drilling in<br />

use of helical interpolation. Easy<br />

to cut! It requires lower spindle<br />

power consumption.<br />

It surprises you that only four tools<br />

can make Ø 13 ~ Ø 65 mm or larger<br />

hole for NC Helix Drill, which benefits<br />

you for tool inventory reduction<br />

and cutting time saved. Here is an example<br />

to show you how the result to<br />

cut multi-stepped hole in AL6061T6.<br />

Less machining time and tool cost.<br />

Besides, the maximum ramping angle<br />

of NC Helix can up to 20 ° whilst others<br />

only 5 ~ 6 °.<br />

For drilling depth, it’s from 2 x DC<br />

for cylindrical shank that has helical<br />

groove design to remove swarf rapidly,<br />

and up to 8 x DC in screw-fit cutter<br />

(with internal coolant) if adapts to our<br />

extension bars or screw-fit tool holder<br />

from market. Besides, it’s not subject<br />

to machine on flat surfaces, but cut<br />

workpiece in irregular surfaces and<br />

variable conditions, such as half hole<br />

on radius, angled surfaces, concave<br />

surface, bolt hole, cross hole and etc.<br />

The serrated cutting edge of insert<br />

cuts chips short and small, and easier<br />

to evacuate and eliminate swarf problem.<br />

P40 and K20F are micro carbide<br />

grades suitable for all kinds of steel,<br />

stainless steel, cast iron, hardened<br />

metals < HRC 50 °, and also recommend<br />

for modern materials such as<br />

Titanium or Inconel 718, or materials<br />

that generate long or soft chips.<br />

In such competitive era, multiapplications<br />

of tools play a crucial<br />

role in cutting industry, along with<br />

inevi table trend of robotics deployment<br />

in production, so it makes NC<br />

Helix Drill a perfect solution in<br />

automation production. If you’d like<br />

to know more product details or applications,<br />

please check our website at:<br />

https://nine9.jic-tools.com.tw/<br />

Welcome to contact us on<br />

trade@jimmore.com.tw<br />

EMO <strong>2019</strong>, hall 5, booth A13<br />



EMO <strong>2019</strong><br />

HALL 5<br />

A08<br />

FASTER.<br />

LONGER.<br />

HARDER.<br />

further information: https://nine9.jic-tools.com.tw/<br />

+49 2154 4992 0<br />

sumitomotool.com<br />

no. 2, August <strong>2019</strong><br />


news & facts<br />

fairs<br />

METALEX <strong>2019</strong><br />

German high tech in metal working<br />

METALEX is the largest international machine tools and<br />

metalworking trade fair in the ASEAN region. Germany<br />

will be the partner country at METALEX in Bangkok. From<br />

November 20 – 23, <strong>2019</strong>, upon the initiative of the VDW<br />

(German Machine Tool Builders’ Association), the German<br />

Federal Ministry of Economics and Energy (BMWi) and<br />

the exhibition and trade fair committee of the Association<br />

of the German Trade Fair Industry (AUMA) will organise<br />

a sector event within the framework of the partner country<br />

participation of Germany. Under the motto “German<br />

High Tech in Metal Working”, German machine tool manufacturers<br />

and companies from the metal-working sector<br />

will present themselves to the Asian specialist public on a<br />

surface area of around 1,200 m 2 . In addition to the joint<br />

stand, the sector event will also offer a special show with<br />

machine demonstrations and a presentation forum.<br />

Top German companies and technology leaders such<br />

as CHIRON-WERKE GmbH & Co. KG, INDEX-Werke<br />

GmbH & Co. KG, E. Zoller GmbH & Co. KG, Gebr. Heller<br />

Maschinenfabrik GmbH, GROB-WERKE GmbH & Co. KG,<br />

Gühring KG and MAPAL Fabrik für Präzisionswerkzeuge Dr.<br />

Kress KG will be represented at the largest metal-working<br />

trade fair in the ASEAN region. Over 30 companies have al -<br />

ready confirmed their participation at the sector event, as<br />

they are convinced by the trade fair and market conditions.<br />


64,000 m 2 exhibition space<br />

100,000 visitors from Thailand and<br />

ASEAN countries<br />

3,300 exhibitors from 50 countries<br />

15 international joint stands<br />

4,800 machines and products on display<br />

METALEX <strong>2019</strong> will open up a new world of smart<br />

metal working technologies, many of which will make<br />

their debuts in ASEAN. This edition will put focuses on<br />

the following profiles amongst many other metalworking<br />

technologies and solutions:<br />

• new technology for metal wire & cable as well as<br />

tube & pipe<br />

• new materials such as aluminum and<br />

lightweight materials<br />

• smart sensors such as micro-electromechanical systems<br />

(MEMS), wireless and the internet of things (IOT)<br />

further information: www.metalex.co.th<br />

bauma <strong>2019</strong><br />

Innovations for concrete cutting and drilling<br />

TYROLIT presented at bauma in Munich special solutions<br />

for the first time. Alongside the WSE811 MKII, the<br />

upgrade of the world’s lightest compact wall saw, the newly<br />

designed wall saw system WSE1621 sets new standards<br />

in wall sawing with ultra- compact and exceptionally<br />

lightweight system components as well as with the new<br />

IoT technology MoveSmart.<br />

The universal and user-friendly WCU17 wire saw, with<br />

up to 17 m wire storage and compatibility with the drive<br />

units and remote controls of other TYROLIT machines, is<br />

the TYROLIT novelty in wire sawing. Another highlight<br />

is the recently CE-certified WS30, a HF wire saw by the<br />

TYROLIT subsidiary Diamond Products.<br />

TYROLIT novelties for the construction trade sector<br />

Right on time for the 100-year anniversary of the company,<br />

TYROLIT presents a completely new, compact dry<br />

cutting assortment that will be adapted within the next<br />

two years. Further highlights are the new range of floor<br />

grinders and floor grinding shoes, the new TBE400 table<br />

saw, as well as the DRS250 core drilling system.<br />

Special project solutions by<br />

TYROLIT project services<br />

Apart from the classic concrete drilling and sawing<br />

equipment, TYROLIT offers a wide range of special tools<br />

and machines for complex projects, like the world’s first<br />

ATEX-certified wire sawing system, as well as the Dolphin<br />

by 1Diamond for environmentally friendly subsea cutting.<br />

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

26 no. 2, August <strong>2019</strong>

fairs<br />

news & facts<br />

Using a grinding machine, Element Six demonstrated<br />

the difference in wear rate between polycrystalline diamond<br />

(PCD) and tungsten carbide, to showcase the extreme<br />

properties of synthetic diamond and the areas in<br />

which it can outperform tungsten carbide. The test highlighted<br />

the potential of PCD as a material to enhance the<br />

performance of tools and machines in the construction<br />

and mining industries.<br />

The findings from the test echoed Bauma’s own key messages<br />

this year around efficiency and sustainability, by<br />

proving the ability to significantly improve the perforbauma<br />

<strong>2019</strong><br />

Element Six showcased synthetic diamond capabilities<br />

Element Six, a world leader in supermaterials and<br />

part of the De Beers Group, showed a live wear<br />

test at the Bauma exhibition.<br />

mance and safety of machinery. Synthetic diamond tools<br />

can exceed standard tungsten carbide tool life by 40 times<br />

for applications such as road milling, reducing downtime,<br />

fuel consumption and machining time, while improving<br />

quality and surface finish.<br />

Speaking at Bauma, Markus Bening, Global Sales Direc tor,<br />

road, mining & wear parts at Element Six, said: “Based on our<br />

experience developing synthetic diamond tools for road<br />

milling and roof bolting applications, we see huge opportuni<br />

ties for OEMs and toolmakers in construction and mining.<br />

Feedback from end-users in Sweden, where synthetic<br />

diamond is today’s standard for road milling jobs, has consistently<br />

shown that the benefits can be game-changing in<br />

terms of increased machining speeds and productivity.<br />

further information: www.e6.com<br />

The next chapter LASERFAIR Shenzhen success story<br />

This year’s LASERFAIR Shenzhen was held from May 8 to 10<br />

at the Shenzhen Convention Center (SZCEC) in southern<br />

China. LASERFAIR Shenzhen has been an annual fixture<br />

since 2015, and this year’s edition was the first one since the<br />

show’s majority acquisition by Hannover Milano Fairs Shanghai,<br />

a subsidiary of Deutsche Messe AG and Fiera Milano.<br />

LASERFAIR Shenzhen covers the full spectrum of laser<br />

applications in manufacturing and is complemented by<br />

a comprehensive program of conferences, among them<br />

the World Laser Manufacturing Conference. This year,<br />

some 170 exhibitors showcased their products and latest<br />

innovations on 7,000 m 2 (75,350 sq. ft.) of display space.<br />

Among them were big-name companies such as Han’s<br />

Laser, Bodor, Laserline and Hymson. 12,843 trade professionals<br />

attended the show.<br />

New context and location as of 2020<br />

In order to further increase the LASERFAIR Shenzhen<br />

show’s international participation and reach a wider trade<br />

audience, it will be staged in future in conjunction with<br />

the new South China International Industry Fair (SCIIF),<br />

starting in 2020. The SCIIF show brings together laser techno<br />

lo gy, automation and robotics, metalworking and di gi tal<br />

factory/IIoT content at one time and place. It will be held<br />

2020, June 2 to 5, at the new Shenzhen World Exhibition<br />

and Conference Center.<br />

further information: www.laserfair.cn<br />



Synthetic Diamond and Cubic Boron Nitride Powder,<br />

MESH and MICRON sizes.<br />

PCD and PCBN, standard discs and specific blanks.<br />

Learn more at www.duratec-superabrasives.com<br />

DURATEC Hartstoffe GmbH<br />

Viktoriastraße 5<br />

42929 Wermelskirchen<br />

Germany<br />

P +49 (0)2196 1050<br />

F +49 (0)2196 2050<br />

info@duratec-gmbh.de<br />

no. 2, August <strong>2019</strong><br />


news & facts<br />

companies<br />

Pioneer in technology of PCD sharpening<br />

by laser ablation<br />

ITA TOOLS Company is a polish manufacturer of<br />

professional cutting tools located in Cracow with<br />

production and service center in Mielec special industrial<br />

zone and warehouse in Wieliczka. In total,<br />

ITA TOOLS employs over 120 workers and offers<br />

a wide range of tools for woodworking industry,<br />

furniture production and processing composite<br />

materials.<br />

Laser ablation has many benefits, compared to<br />

the traditional methods of sharpening processes,<br />

such as:<br />

• the sharpening area doesn’t warmup<br />

• ultimate precision especially for DIA profile<br />

cutting edges; thanks to the laser we are<br />

able to sharpen any angle<br />

• the possibility to sharpen chip breakers<br />

• after laser ablation the cutting blade is<br />

more acute, the laser cuts not eroding<br />

• the laser cuts PCD and binder concurrent<br />

• simple processing of coarse PCD<br />

• expanding tool lifes<br />

• no harm for the ecology<br />

Laser ablation works by focusing a laser onto a substrate<br />

to remove mate rial that is on it’s surface. The amount that is<br />

removed depends on the intensity, pulse length, and wavelength<br />

of the laser, as well as the material itself. The area<br />

absorbs the laser that is being directed on it, thereby breaking<br />

down the chemical bonds within the area. Laser ab -<br />

lation is a very efficient, reliable and cost-effective method<br />

further information: www.itatools.pl<br />

3D Systems and GF Machining Solutions<br />

expand partnership in Greater China<br />

3D Systems and GF Machining Solutions, a division<br />

of Georg Fischer AG, announced an expanded<br />

partnership in the Greater China region that<br />

will enable customers in the world’s leading manufacturing<br />

region to enhance their metal parts<br />

produc tion and redefine their manufacturing<br />

environments.<br />

By combining the strength of 3D Systems’ innovation<br />

and expertise in additive manufacturing with GF Machining<br />

Solutions’ renowned leadership in precision machining<br />

and industrial automation, manufacturers will now be<br />

able to produce more efficiently complex metal parts within<br />

tight tolerances, and reduce total cost of operation.<br />

“The Chinese and Taiwanese markets<br />

are known for global manufacturing<br />

leadership,” said Herbert<br />

Koeck, executive vice president and<br />

general manager, global go to market,<br />

3D Systems. “Manufacturers in<br />

this region are looking for ways to<br />

transform their production work -<br />

flows in order to maintain their competitive<br />

position. Our joint metal<br />

3D printing solutions with GF<br />

Machining Solutions fit seam less ly<br />

into the traditional shop floor and<br />

are unmatched in the industry.”<br />

As of August 1, <strong>2019</strong> manufacturers<br />

in China and Taiwan will<br />

28 no. 2, August <strong>2019</strong>

companies<br />

news & facts<br />



FOR<br />



be able to order 3D Systems’ and GF Machining Solutions’<br />

co-branded scalable metal additive manu facturing solutions<br />

(i.e., DMP Factory 500, DMP Factory 350 and DMP<br />

Flex 350) exclusively through GF Machining Solutions.<br />

The companies’ co-branded solutions - which integrate<br />

traditional and additive manufacturing technologies - are<br />

a new concept in scalable, digital factory automation that<br />

includes software for digital production workflows, including:<br />

enhanced part design, 3D printers, materials, electrical<br />

discharge machining (EDM), milling equipment, advanced<br />

post-processing technologies, and services. These new design<br />

and manufacturing options can lead directly into improved<br />

existing products, innovative new designs, new business<br />

models, and new markets.<br />

Customers in the Greater China region will also have<br />

access to GF Machining Solutions’ Customer Innovation<br />

Center (CIC) in Shanghai. Engaging with the CIC provides<br />

customers with the ability to consult and collaborate with<br />

experts from 3D Systems and GF Machining Solutions to<br />

develop applications with metal 3D printing solutions<br />

which include materials, services, hardware and software.<br />

As part of this process, manufacturers will have the ability<br />

to benchmark their parts and products to ensure quality<br />

control and validate final parts against specifications -<br />

ulti mately saving them time, money, and providing faster<br />

time to market.<br />

“China and Taiwan are strategic key markets for GF<br />

Machining Solutions where we support our customers<br />

with an organization of more than 350 direct applications,<br />

service and sales personal,” said Laurent Castella, head of<br />

market region Asia, GF Machining Solutions. “We are delighted<br />

to enhance the support to our customers in the<br />

transition towards additive manufacturing, with our new<br />

Customer Innovation Center (CIC) in Shanghai and by a<br />

dedicated group of additive manufacturing experts.”<br />

3D Systems and GF Machining Solutions have a presence<br />

in more than fifty countries, which includes production<br />

facilities, research and development centers, and broad<br />

sales and service networks encompassing internal teams as<br />

well as channel partners.<br />

information: www.gfms.com / www.press@3dsystems.com<br />

EMO <strong>2019</strong><br />

HALL 3, BOOTH C10<br />

solutionteam@ceramtec.de<br />

www.spk-tools.com ∙ www.ceramtec.com<br />

no. 2, August <strong>2019</strong><br />


news & facts<br />

companies<br />

EMVA appoints new<br />

Standards Manager<br />

Werner Feith coordinates standardization<br />

activities of the association<br />

The European Machine Vision Association (EMVA) has<br />

appointed Werner Feith as new EMVA Standards Manager.<br />

Werner will be responsible to promote the European machine<br />

vision standardization activities worldwide and to<br />

coordinate the development process of machine vision<br />

standards; as well as to identify new standardization needs<br />

in a rapidly changing industrial environment.<br />

Werner Feith received his education from TU München<br />

as a solid state physicist. After some time with industrial<br />

computer industry he founded Sensor to Image GmbH,<br />

which started as a frame grabber company, but was soon<br />

tuned to be an FPGA IP company supporting digital camera<br />

interfaces defined by Gencam standard. Sensor to<br />

Image became and is the world leader in industrial camera<br />

interface IP supporting GigEVision, USB3-Vision and<br />

CoaXPress. After selling Sensor to Image in 2017 Werner<br />

Feith was attracted by the open position as EMVA Stan-<br />

EMVA Standards Manager<br />

Werner Feith<br />

dards Manager to continue<br />

his career in the industry<br />

and share his vast experience<br />

in standardization.<br />

Since 15 years, the European<br />

Machine Vision Association<br />

(EMVA) is hosting the development<br />

of standards for the machine vision industry with<br />

the now well-known and widely used standards GenICam<br />

and EMVA1288. GenICam standardizes the high level<br />

inter facing of a vision device and a compu ter. EMVA1288<br />

is a characterization and specification pro cedure for image<br />

sensors and cameras used in machine vision. With the<br />

Industrial Embed ded Vision Interface Stan dard and the<br />

Open Optics Camera Interface Standard the EMVA currently<br />

leads two new standard initiatives.<br />

further information: www.emva.org<br />

Intelligent ultrasonic system for<br />

lapping and polishing<br />

Systematically further developed, with more power,<br />

well thought-out and with an elegant design summarises<br />

what the ENESKAsonic, the new ultrasonic<br />

system from the joke family, is all about.<br />

Whether grinding, lapping, milling, polishing,<br />

deburring, welding or cleaning is involved:<br />

joke Technology (formerly Joisten & Kettenbaum)<br />

has been a leader in the field of surface technology<br />

for more than 79 years.<br />

It is ideal for workpieces with a complex geometry and<br />

is versatile in use. Particularly in the field of eroding and<br />

punching, calling for extremely precise edges or highly<br />

abrasive work with hard materials, the system can be<br />

exploited to the full with an output of 45 W. The “100 %<br />

Made in Germany” system was presented officially at the<br />

Moulding Expo <strong>2019</strong>.<br />

Intelligent user friendliness took top priority during development.<br />

With clearly arranged display and central rotary<br />

controller, the ENESKAsonic is intuitive and easy to use.<br />

The look, feel and the design of the new housing are convin<br />

cing with its compact dimensions of only 135 x 235 x<br />

200 mm. The integrated carrying handle shows how well<br />

thought-out the design is. No conversion, folding out or locking<br />

is necessary - simply grasp and change the workplace.<br />

Easy control via touch display<br />

The new touch display shows all the relevant information<br />

(ranging from output, including frequency, to boost<br />

function) at a glance. Individual, memorised settings can<br />

be called up by double-clicking. Colored LEDs and acoustic<br />

signals provide the user direct feedback as to which pa-<br />

rameters are configured and whether for example a handpiece<br />

is correctly connected or in use. Contrast and brightness<br />

in the display can be adjusted, which is particularly<br />

con venient when changing workstations. The integrated handpiece<br />

support is also practical. The idle timer detects unused<br />

handpieces and protects against wear and tear - and is<br />

in di vi dually adjustable from between 0 - 120 min. The<br />

ENESKA sonic is convenient and versatile with the option<br />

for a further handpiece - different tasks with various different<br />

settings can be performed in quick alternation.<br />

“Tune up the frequency”<br />

When polishing and lapping, the ENESKAsonic works<br />

within a frequency range of 20 to 30 kHz. The frequency<br />

of the handpiece, which weighs only 140 g, is now infin<br />

itely adjustable - a major advantage during daily use. It<br />

allows ergonomic and fatigue-free work, wherever finest<br />

stock removal is required. The ENESKAsonic determines<br />

the correct frequency for the clamped tools automatically<br />

with the new Tune function. Workpieces can thus be processed<br />

better in depth, ceramic fibre files do not need to be<br />

shortened and can be optimally used at any length.<br />

30 no. 2, August <strong>2019</strong>

companies<br />

news & facts<br />

This allows a markedly longer service life overall and accurate<br />

stock removal. Boost mode is available for power-intensive,<br />

extra abrasive work with sintered diamond files -<br />

everything at full power. A cooling system integrated in the<br />

control prevents the powerful electronics from overheating.<br />

An external LED cold light source can be connected<br />

or software extensions can be installed in the future via<br />

a USB interface. A further advantage: ENESKA 2-1 series<br />

handpieces can continue to be used; only the connecting<br />

cable needs changing.<br />

further information: www.joke.de<br />

First Neo laser processing machine<br />

in North America<br />

“Cycle times are money”<br />

In the spring of <strong>2019</strong>, the first Neo laser processing<br />

machine was delivered to North America. The<br />

customer who invested in this machine was<br />

Shape-Master Tool Company from Kirkland,<br />

Illinois, about an hour and a half away from<br />

Chicago by car. Shape-Master was founded in<br />

1976 as a manufacturer of natural diamond tools.<br />

Today, the company is one of the leading producers<br />

of polycrystalline cutting tools in North<br />

America, offering the industry’s best edge quality.<br />

In addition, Shape-Master in the USA is a<br />

pioneer in the application of laser technology in<br />

this product range and thus the ideal user for the<br />

Neo machine.<br />

From Don Spolum, President of the Shape-Master Tool<br />

Company, we wanted to know what aspects have led to<br />

this investment and what hopes and expectations are<br />

associated with it.<br />

Don, the Midwest United States, where Shape-Master is<br />

located, has a very strong industrial base. Why do your<br />

customers choose Shape-Master over a competitor?<br />

Don Spolum: Our specialty is custom tools. We produce<br />

the right cutting edge, the right geometry and the most<br />

efficient solution for each application. With such orders,<br />

we can play out our flexibility and there we are usually<br />

much faster than the competition. In concrete terms, this<br />

means that we deliver customized tools on average twice<br />

as fast as other providers. Of course, we also offer standard<br />

tools. However, we value quality and precision in everything<br />

we do.<br />

How do you manage to be so much faster in terms of<br />

delivery dates than other providers?<br />

Don Spolum: This is not least a question of the equipment<br />

with which we produce. We try to have the most<br />

productive and modern equipment in our house. Look, we<br />

want to do our job. We want to do it in high quality. And<br />

we want to be fast and optimize our costs. My personal<br />

approach is to be superior to our competitors in terms of<br />

equipment and to work as efficiently as possible. If we succeed,<br />

or since we succeed, we can deliver the right tools to<br />

our customers within a short time.<br />

Let’s talk about the Neo. With this investment you have decided<br />

not only for a machine but also for the combined process of<br />

laser roughing plus finishing on the grinding machine. Why?<br />

Don Spolum: We will always continue to try and find<br />

new ways we can get an order out the doors as fast and<br />

efficient as possible. So, if the combined process of laser<br />

roughing and grinding helps us to expedite cycle times,<br />

well then it’s welcome. Cycle times are money.<br />

In addition to PCD, will you be processing other super-hard<br />

materials as well with the Neo?<br />

Don Spolum: We manufacture tools from both PCD and<br />

PCBN. In this respect, we will not only use the Neo for preprocessing<br />

PCD. I assume that the Neo will also help us<br />

with different PCBN applications. We’re always open to<br />

learning new things and see how things work. You know,<br />

the more we can learn, the better our decisions will be,<br />

the more efficient we will be and the more our customers<br />

will benefit.<br />

Did Shape-Master have any arguments against the Neo before<br />

making the investment decision?<br />

Don Spolum: No, not really. There was one point that<br />

we critically discussed. This concerned the manual operation<br />

of the machine. That makes sense in small series. But<br />

if we’re talking about lot sizes that span several hundred<br />

tools, then you will not be able to avoid an automation<br />

solution at least not if you want to exploit the full efficiency<br />

of the machine.<br />

How do you experience working with Agathon?<br />

Don Spolum: Well, I think our common history speaks<br />

for itself. We had the first Agathon 350 Combi EcoDress<br />

and the Agathon first Evo Penta here in the US. We work<br />

together well and we have a good relationship. I mean, it’s<br />

been very good and awesome. But most important is service<br />

and response times. There are other machine builders<br />

on the market. But are they able to respond quickly when<br />

needed? Are they able to make sure the machines are up<br />

and running? Well, Agathon gives us the service we need.<br />

So we are happy with that.<br />

further information: www.agathon.ch<br />

no. 2, August <strong>2019</strong><br />


news & facts<br />

companies<br />

LEUCO receives German Innovation Award<br />

The prize that makes innovations visible<br />

LEUCO received a “WINNER” award at the<br />

German Innovation Awards for its “LEUCO<br />

AirStream” milling system for woodworking.<br />

The disposal of chips is a classic challenge in woodworking.<br />

Constructive solutions to tools for targeted chip guidance<br />

have to a certain extent been available for some time<br />

in the industry, especially in the furniture industry. “The<br />

AirStream was inspired by the scoops of sports cars. Transferring<br />

the design to woodworking tools was a new tricky<br />

and exciting task that has never before been applied in<br />

this way,” reports Benjamin Sitzler, developer of the Air-<br />

Stream system at LEUCO.<br />

In the category “Excellence in Business to Business”, section<br />

“Machines & Engineering”, the AirStream system solution<br />

convinced and was honoured with the award Winner.<br />

The jury deliberately honors innovations that are<br />

available on the market and makes them consciously visible<br />

through the award.<br />

German Innovation Award<br />

The prize is awarded to innovations that have a<br />

lasting effect. The German Innovation Award does<br />

not merely honour innovations, but those that<br />

demonstrably generate added value for the user.<br />

Even when it comes to the details of an overall<br />

solution, the focus must be on radical user<br />

centricity and thus on the individual.<br />

The AirStream System is characterised by its targeted,<br />

intelligent guidance of the resulting chips in the direction of<br />

extraction. The advantage for the user is that 99 % of the<br />

chips are sucked off, i.e. the machine remains clean and<br />

virtually does not have to be cleaned.<br />

In addition, the tool life of the milling cutter is longer, as<br />

the cutting edges do not have to perform unnecessary<br />

double cutting work. The targeted guidance of the air<br />

flow also results in less uncontrolled air turbulence,<br />

and the tool is pleasantly quiet in use for the user.<br />

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


Sales and production site in India<br />

For 55 years ZECHA Hartmetall-Werkzeugfa<br />

bri ka tion GmbH has been synonymous for<br />

precision and quality in micro-machining,<br />

blanking and forming tools spanning a vast<br />

range of sectors. The objective has always been<br />

clearly defined: The provision of the best possible<br />

customer solutions - for every application, every<br />

material and however small the scale.<br />

In order to be able to ensure a swift and flexible supply<br />

of high quality tool solutions to customers worldwide,<br />

ZECHA relies on maxi mum customer proximity and an<br />

extremely close cooperation with reliable partners.<br />


ZECHA is suitably represented in the Asian region.<br />

The move is an important strategic step in the expansion<br />

of the Asian market. ZECHA has operated an Indian-<br />

German joint venture with ZECHA PRECISION TOOLS<br />

LIMITED (formerly Dagger Master Tools Limited), since<br />

1999. It has allowed ZECHA to provide a professional contact<br />

point for customers and their current needs for high<br />

quality tool solutions. ZECHA has established its extremely<br />

high production and quality standards on site, which is<br />

why the renaming of the company into ZECHA PRECISION<br />

TOOLS LIMITED on April 24, <strong>2019</strong>, was the next logical<br />

step in the successful partnership.<br />

ZECHA PRECISION TOOLS LIMITED has been successfully<br />

manufacturing high quality solid carbide microtools<br />

since 1980 and also represents leading Swiss and German<br />

precision machine and accessory brands in India. The tool<br />

range consisting of catalogue products and individual tool<br />

solutions fulfils the highest demands for precision, geometric<br />

accuracy, quality and process capability.<br />

further information: www.zecha.de<br />

32 no. 2, August <strong>2019</strong>

companies<br />

news & facts<br />

A successful year for the MAPAL Group<br />

Almost 5 % growth in 2018<br />

The international MAPAL Group posted growth of<br />

almost 5 % in 2018.<br />

“The results that we achieved last year are quite satisfactory,”<br />

says Dr Jochen Kress, President of the MAPAL Group.<br />

Consolidated Group turnover climbed from € 610 million<br />

in 2017 to € 640 million in 2018. In addition to turnover,<br />

the number of employees also increased. The precision<br />

tool manufacturer now has more than 5,500 employees<br />

worldwide, with over 3,600 in Germany.<br />

MAPAL has consolidated and further expanded its position<br />

in all major regions. To achieve this substantial investments<br />

in the locations were made in the past year. “In<br />

Asia, we founded a new joint venture in Vietnam and acquired<br />

the majority stake in ADICO, a manufacturer of<br />

PCD and PCBN cutting materials,” specifies Kress. Asia<br />

is still the second most important market for MAPAL after<br />

Germany, even though growth rates in China have decreased<br />

somewhat in line with the country’s overall economic<br />

growth. The Group is also strengthening its presence<br />

in the Americas. “We have expanded our location in<br />

Fountain Inn, South Carolina,” explains Dr Jochen Kress.<br />

A completely new plant was also opened in Mexico in<br />

February <strong>2019</strong>.<br />

MAPAL is increasing<br />

its involvement in various<br />

industries, including<br />

tool and mould<br />

mak ing. There are challenges<br />

ahead in the automotive<br />

industry, too,<br />

says Kress: “We intend<br />

to build on our leading<br />

position in machining<br />

components for electric<br />

vehicles.”<br />

There is also a continued<br />

focus on di gi ta -<br />

li sa tion and thus on<br />

MAPAL’s subsidiary<br />

Dr. Jochen Kress,<br />

president MAPAL Dr. Kress KG<br />

c-Com, which has<br />

broadened its focus. “We have seen in practice what many<br />

companies are lacking, especially small companies, and<br />

that is something that makes access to the digital market<br />

easier for them,” says Kress. For this reason, c-Com offers a<br />

range of modules<br />

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

With a century’s worth of experience<br />

we find the best solution for any<br />

application you can think of.<br />

Discover the innovative TYROLIT grinding tools for<br />

high-precision applications at www.tyrolit.com<br />

Visit us<br />

hall 11, booth D06<br />

Premium grinding tools since 1919<br />


news & facts<br />

companies<br />

TSUBAKI focuses on continuity<br />

On July 1, Henning Preis (49) took over as president<br />


KABELSCHLEPP GmbH-Hünsborn. At the same time,<br />

Michael Diebel (53) was appointed COO of KABELSCHLEPP<br />

GmbH-Hünsborn. Kevin Powers, the previous managing<br />

director, moves to the board of the traditional mediumsized<br />

company and will also be taking on more tasks within<br />

the US TSUBAKI Holding.<br />

With the new members of the management, TSUBAKI as<br />

the holding company and KABELSCHLEPP are focusing on<br />

continuity in the management<br />

of the globally<br />

active company.<br />

The two managers,<br />

who reported to Kevin<br />

Powers until the end<br />

of June, had each already<br />

been responsible<br />

for the business areas<br />

of Cable Carriers and<br />

CAPS (Conveyor & Protection<br />

Systems). This<br />

ensures continuity in<br />

management and orien -<br />

On July 1, Henning Preis took over<br />

as president & CEO of TSUBAKI<br />


KABELSCHLEPP GmbH-Hünsborn<br />

tation of the company.<br />

Henning Preis has<br />

been with the German<br />

company for a good<br />

three years already.<br />

The business graduate previously held different management<br />

positions within the SMS Group, including five years<br />

in Brazil.<br />

His counterpart Dipl.-Ing. Michael Diebel moved to<br />

KABELSCHLEPP from a managing position with world<br />

market leader Rittal in 2007. Since then, he has been responsible<br />

worldwide for the CAPS business area, which<br />

he now still heads up as managing director and COO of<br />

KABELSCHLEPP GmbH-Hünsborn. “The global presence<br />

of KABELSCHLEPP with a focus on Europe and<br />

Asia is a particular<br />

strength. As<br />

a member of the<br />

TSUBAKI Group,<br />

globally active<br />

cus tomers can be<br />

supplied from local<br />

production in<br />

all worldwide relevant<br />

industrial regions,”<br />

concludes<br />

Diebel.<br />

Michael Diebel was appointed COO of<br />

KABELSCHLEPP GmbH-Hünsborn<br />

further information: www. tsubaki-kabelschlepp.com<br />

New Technology & Education Centre<br />

Development of turnkey cutting solutions<br />

Mitsubishi Materials has opened a new technology center<br />

- MTEC (Mitsubishi Technology & Education Centre) near<br />

Stuttgart, Germany. The new center is housed in a modern<br />

two-storey building and was officially inaugurated with an<br />

opening ceremony on June 4th, <strong>2019</strong>.<br />

This state-of-the-art facility represents significant investment<br />

for the present and future needs of Mitsubishi’s<br />

development towards providing customers with turnkey<br />

metal cutting solutions. To achieve this, MTEC houses the<br />

latest high-technology turning, milling and Swiss type<br />

machine tools, including a 5-axis machining center. These<br />

new machines are complemented by advanced coordinate<br />

measuring and quality inspection devices, together with<br />

the latest in tool setting equipment.<br />

Yutaka Tanaka, President of MMC Hardmetal Europe<br />

(Holdings) GmbH (the European Headquarters of<br />

Mitsubishi Materials Metalworking Solutions Company)<br />

says “It is our expectation that this exciting new facility<br />

will become well respected for providing a closer, direct<br />

engineering contact with our customers. We aim to<br />

give them answers that will provide improvements to their<br />

application processes, as well as using our engineering<br />

expertise for more advanced turnkey projects. MTEC<br />

will also offer an important test bed for our own cutting<br />

tool development and form strong links with Mitsubishi’s<br />

other global technical centers in Japan, China, Thailand,<br />

Spain and the USA. This link will enable a greater sharing<br />

of accumulated machining data for the benefit of our<br />

customers”.<br />

The center is staffed by personnel from the European<br />

project engineering team who will make this their new<br />

home base. The team currently consists of twelve employees<br />

and will expand as demand for their services increase. The<br />

opening of MTEC Stuttgart is a milestone in Mitsubishi’s<br />

history as it operates as a driving force for building synergies,<br />

strengthening the collaborative framework between<br />

Mitsubishi and international machine tool builders.<br />

Mitsubishi Materials now operates two MTEC centers<br />

in Europe, the other being in Valencia, situated close to<br />

its production plant there.<br />

further information: www.mmc-hardmetal.com<br />

34 no. 2, August <strong>2019</strong>

companies<br />

news & facts<br />

First year as standalone company<br />

Global hard and super-hard materials leader poised for<br />

continued growth<br />

Hyperion Materials & Technologies, an advanced material<br />

science leader responsible for groundbreaking manufacturing<br />

technologies, recently marked its first year as an independent<br />

company following an investment from KKR and<br />

is moving forward on a path of growth and development.<br />

“In just a year, we have cemented the leadership team,<br />

established an independent presence around the world and<br />

engaged our entire workforce through an employee equity<br />

program, all of which has allowed us to focus even more<br />

on innovating for our customers and creating best-in-class<br />

products,” said Ron Voigt, CEO of Hyperion.<br />

One recent example includes the spring launch of the<br />

BZN Compacts VS-Series, which features a new chain of<br />

polycrystalline cubic boron nitride (PCBN) grades for fabrication<br />

into tools capable of higher levels of productivity,<br />

precision and consistency in hardened steel turning and<br />

milling and powder metal machining. Another key advancement<br />

includes the successful industrialization of diamond-faced<br />

carbide valve and seat sub-assemblies used in<br />

Rotary Steerable System (RSS), a directional drilling tool for<br />

a major oil and gas client. Hyperion also developed unique<br />

concepts and solutions for vitrified cubic boron nitride<br />

(CBN) grinding applications.<br />

While Hyperion Materials & Technologies is a relatively<br />

new name in the industrial world, the company has a rich<br />

legacy of expertise founded on decades of important scientific<br />

breakthroughs. Hyperion formed in July 2018 through<br />

KKR’s acquisition of Sandvik’s hard materials division,<br />

Sandvik Hyperion. Sandvik, founded in 1862, is a Swedenbased<br />

global engineering group and was one of the first to<br />

start producing cemented carbide in the early 1940s. Commonly<br />

referred to as tungsten carbide, this material is one<br />

of the most successful engineered composites ever produced.<br />

Its unique combination of strength, hardness and<br />

toughness satisfies numerous demanding applications. In<br />

2014, Sandvik Hyperion was formed through the merger<br />

of Sandvik Hard Materials and Diamond Innovations, which<br />

had evolved from GE Superabrasives, the company that<br />

originally synthesized the first man-made diamond in the<br />

1950s. While people often think of diamonds in jewelry,<br />

synthetic diamond materials are used in a wide range of<br />

industrial applications to cut, grind, lap, polish and coat<br />

other materials. Diamond Innovations also pioneered the<br />

use of cubic boron nitride (CBN) for cutting and grinding<br />

applications.<br />

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

INFO:<br />

VDW – Generalkommissariat EMO Hannover <strong>2019</strong><br />

Verein Deutscher Werkzeugmaschinenfabriken e.V.<br />

Corneliusstraße 4 · 60325 Frankfurt am Main · GERMANY<br />

Tel.: +49 69 756081-0 · Fax: +49 69 756081-74<br />

emo@vdw.de · www.emo-hannover.de<br />

MPI19031_dihw_180x126,5_de.indd 1 08.04.19 14:31<br />

no. 2, August <strong>2019</strong><br />


processes<br />

Milling cutters for the<br />

new generation<br />

Producing reliable purpose-built tools<br />

Machining structural parts<br />

for aircraft reliably, cost-effectively<br />

and without defects calls<br />

for purpose-built tools. Czech<br />

civil aircraft manufacturer<br />

Aircraft Industries depends on<br />

milling cutters for high-volume<br />

machining from MAPAL to get<br />

the job done.<br />

The story of Aircraft Industries began<br />

in 1936. Since then, the company,<br />

based in Kunovice in the Czech<br />

Republic, has built more than 8,000<br />

aircrafts of various types. The manufacturer<br />

is currently focusing primarily<br />

on the latest generation of its<br />

L 410 model, the L 410 NG, which entered<br />

series production last year. The<br />

standard version of the aircraft, 90 %<br />

of which consists of aluminium parts,<br />

is designed for short-haul flights. The<br />

multipurpose aircraft can transport<br />

19 passengers and is also used for<br />

transporting cargo from remote areas<br />

to major cities.<br />

The aircraft L410 NG is the latest<br />

generation that Aircraft Industries<br />

produces<br />

The L 410 NG represents a significant<br />

improvement on its predecessor,<br />

featuring a new wing structure that<br />

allows for higher fuel capacity and<br />

thus a longer range. It is also fitted<br />

with more powerful engines and cutting-edge<br />

avionics.<br />

Manufacturing parts quickly<br />

and efficiently<br />

In preparing for the production<br />

of parts for the aeroplane, Aircraft<br />

Industries revised its approach to machining<br />

and, in 2015, installed a new<br />

horizontal machining center for hig<strong>hp</strong>erformance<br />

aluminium machining.<br />

“This enables us to manufacture our<br />

parts more quickly and efficiently,”<br />

say Libor Krchň áč ek and Oldř ich Zich<br />

from Aircraft Industries, explaining<br />

their decision to purchase the equipment.<br />

At the same time, the company<br />

was in the market for tools that satisfied<br />

its requirements with regard to<br />

machining speed, durability and surface<br />

quality.<br />

Parts for the L 410 NG - the skin on<br />

the upper and lower surfaces of each<br />

wing, which forms the outer shape of<br />

the wing, as well as the integral subframe<br />

and fuselage sections - are machined<br />

from large blocks of aluminium.<br />

“MAPAL’s glowing references and<br />

experience in aluminium machining<br />

made it our first port of call when we<br />

were drawing up the process for machining<br />

the aircraft skin,” the responsibles<br />

from the Aircraft Industries<br />

team recall. For milling machining,<br />

Aircraft Industries contacted Petr<br />

Macho, who is MAPAL’s technical<br />

consultant responsible for the Czech<br />

Republic.<br />

PCD milling cutters offer<br />

impressive performance<br />

across the board<br />

“We conducted some exploratory<br />

trials with a PCD-tipped high-feed<br />

milling cutter, and the customer was<br />

thrilled with the tool right from the<br />

start,” recalls Petr Macho. The fourbladed<br />

milling cutter, which is designed<br />

specifically for machining convex<br />

surfaces, has a diameter of 20 mm<br />

and features a special toroidal geometry.<br />

At a spindle speed of 23,000 rpm<br />

and a cutting speed of 1,445 m/min,<br />

it produces an average surface roughness<br />

of between 0.4 and 0.8 µm. “We<br />

are very happy both with the surface<br />

and with the tool life of the milling<br />

cutter,” say Libor Krchň áč ek and<br />

Oldř ich Zich.<br />

Starting with this first tool, the<br />

partnership gradually grew broader.<br />

“Once we had made effective use of<br />

the PCD milling cutter for machin-<br />

from left: Libor Krchň áč ek and Oldř ich Zich<br />

(Aircraft Industries) discuss the machining<br />

with Petr Macho (MAPAL)<br />

ing the surface of the wing skin, we<br />

tested solid carbide milling cutters<br />

for machining the integral subframes<br />

of the main wing,” recalls Libor<br />

Krchň áč ek. As Oldř ich Zich adds, “We<br />

are absolutely delighted with the machining<br />

quality and reliability of<br />

these tools as well.” To rough machine<br />

the entire structure, including<br />

the pockets, the company uses the<br />

SPM-Rough high-performance milling<br />

cutter with a corrugated profile.<br />

It impresses with high material removal<br />

rates, excellent rigidity and<br />

perfect chip flow at high machining<br />

values. For example, it is capable<br />

of operating at a feed rate up to 13 m/<br />

min. “The bottom panel of the wing,<br />

which is part of the fuel tank, is made<br />

from 2000 kg of material - and after<br />

35 hours, 73 kg is all that is left,” says<br />

Krchň áč ek.<br />

Aircraft Industries uses a solid carbide<br />

milling cutter from the SPM series<br />

for finishing the structures of the<br />

The inside shape of the wing made of<br />

aluminium is machined with MAPAL tools<br />

36 no. 2, August <strong>2019</strong>

processes<br />

GrindTec<br />

Aircraft Industries not only produces the components,<br />

but also completely assembles the aeroplanes<br />

main wing as well. It features polished chip flutes that ensure that chips are<br />

removed reliably. “This was another milling cutter that delivered optimal results<br />

right from the first test,” says Macho. The result is that all three tools are<br />

now being used to great effect for manufacturing various parts of the aircraft.<br />

“What matters to us is that the tools we use are reliable and provide accuracy<br />

of repetition while still being cost-effective,” stresses Zich, “and all of that is<br />

exactly what we get from the MAPAL tools.”<br />

From parts manufacturing to final assembly<br />

It is little wonder, then, that the decision-makers at Aircraft Industries not<br />

only employ MAPAL tools for manufacturing parts but are also considering<br />

using them for final aircraft assembly. “The latest stage in our partnership<br />

has involved carrying out tests with combination tools for reaming and countersinking<br />

for hand drills to machine the rivet bores,” says Macho. Aircraft<br />

Industries has also tested a MAPAL reamer for reaming H8 bores in the aircraft<br />

interior. These tests, too, have been successful, which means that MA-<br />

PAL tools will no longer be limited to parts manufacturing but will soon be<br />

appearing in final assembly at the Aircraft Industries factory in Kunovice.<br />

GrindTec<br />

2020<br />

World‘s leading trade fair<br />

for Grinding Technology<br />

March 18-21, 2020<br />

Messe Augsburg<br />

Great results for the 643 exhibitors,<br />

top grades by 19,100 visitors from<br />

54 nations:<br />

92 %<br />

6 % 2 %<br />

Aircraft Industries uses<br />

different milling cutters, drills<br />

and reamers from MAPAL.<br />

from left: Reamer for H8 bores,<br />

milling cutters for finishing<br />

and roughing the pockets,<br />

PCD high feed milling cutter<br />

and a combination tool for<br />

reaming and countersinking<br />

for hand drills to machine<br />

the rivet bores<br />

92 % of the exhibitors * assigned<br />

marks 1 („very good“), 2 or 3 for<br />

their commercial results. 6 % were<br />

content with them. Only 2 % were<br />

not content with their results,<br />

assigning a 5 or 6.<br />

* Gelszus Messe-Marktforschung, Dortmund<br />

Information +<br />

participation documents<br />

www.grindtec.de<br />

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

Technical sponsor: FDPW Fachverband der<br />

Präzisionswerkzeugmechaniker, www.fdpw.de<br />

Organiser: AFAG Messen u. Ausstellungen GmbH<br />

Am Messezentrum 5, 86159 Augsburg, www.grindtec.de

processes<br />

Productive PCD precision machining<br />

PCD tools today<br />

authors:<br />

• Dr. Stephan Scholze, Josquin Pfaff, Agathon AG (Bellach, Switzerland)<br />

• Dr. Karl Mayrhofer, Gunter Steckel, Tyrolit Schleifmittelwerkzeuge Swarovski KG (Schwaz, Austria)<br />

• Jana Haas-Wittmüß, Chris Graham, Element Six (UK) Ltd. (Oxford, United Kingdom)<br />

Agathon, Element Six and Tyrolit have developed<br />

a com pre hens ive solution for economi cal<br />

and quality-oriented ma chining of polycrystalline<br />

dia mond (PCD) grades ranging from ultra-fine to<br />

coarse grain sizes.<br />

The demand for tools made from polycrystalline diamond<br />

(PCD) is constantly increasing. The development is<br />

driven by growing demands for the latest materials, such<br />

as carbon fibre reinforced plastic (CFRP), their composites<br />

(e.g. Al-Ti-CFRP stacks) as well as titanium and aluminium<br />

alloys. With the growing demand, batch sizes in tool production<br />

are also increasing, frequently reaching doubledigit<br />

or triple-digit figures. However, more than 50 % of indexable<br />

inserts fitted with PCD are produced in small to<br />

medium sized companies (SMEs).<br />

laser roughing, an Agathon Neo was used. Ground blanks,<br />

which were fitted with PCD segments on one side, were<br />

used as test material. The five different PCD specifications<br />

of Element Six on table 1 are part of the investigation. In<br />

the tests, inserts with the geometry DCMW11T304 were<br />

made from these (see illustration 1).<br />

SMEs particularly feel the increased cost pressure caused<br />

by international competition. The manufacture of PCD<br />

tools is demanding and rejects can be generated late in the<br />

chain. SMEs are often limited with regard to a freely available<br />

investment budget and consequently by the machine ry<br />

available to them.<br />

Thus, these manufacturers are looking to produce their<br />

PCD tools in the most economical way possible. The economic<br />

calculation can be influenced positively by many<br />

parameters: short processing time, short re<strong>tooling</strong> times,<br />

minimal rejects, low costs of consumables, low<br />

tool costs and of course low costs for the purchase<br />

of the necessary machinery. Many of<br />

those factors can be influenced very positively<br />

by the hybrid process strategy described in this<br />

article: pre-machining with laser, finishing by<br />

grinding.<br />

Method of investigation<br />

Agathon, Element Six and Tyrolit have jointly<br />

investigated how productivity and process capability<br />

of PCD tool machining can be improved.<br />

For this, numerous tests for pre-machining and<br />

finishing were carried out. The results are now<br />

available.<br />

Economically two process variants are compared:<br />

pre-machining and finishing on one<br />

grinding center as well as pre-machining with<br />

the laser followed by finishing by grinding. An<br />

Agathon Dom Plus with emulsion as cooling<br />

lubricant was used as a grinding center. For<br />

designation<br />

illustration 1: Indexable insert with final geometry<br />

DCMW11T304, carbide base body with brazed-on<br />

PCD segment<br />

PCD<br />

grade<br />

PCD layer<br />

thickness<br />

[µm]<br />

PCD layer<br />

specification<br />

range [µm]<br />

characteristics<br />

A CTB010 300 200 - 450 10 µm average grain size.<br />

CTB010 is the workhorse PCD<br />

B CTB010 500 400 - 600<br />

grade ideal for many applications<br />

where a good balance<br />

C CTB010 700 530 - 880<br />

of toughness and wear<br />

resistance is required.<br />

D CTM302 500 400 - 600<br />

E CMX850 500 350 - 650<br />

table 1: PCD specifications<br />

A multi-modal PCD with<br />

a combination of 2 μm to<br />

30 μm grain sizes which gives<br />

CTM302 excellent wear<br />

resistance, edge strength<br />

and edge quality.<br />

As the finest grain grade, with<br />

a mean grain size of

processes<br />

Pre-machining with the grinding center<br />

In the second test series, the impact of the PCD volume<br />

on the grinding forces was investigated in more detail. For<br />

this, the inserts were initially roughed with a D25 layer to<br />

an exact inscribed circle measurement of 9.58 ± 0.01 mm<br />

(PCD segment and carbide base body). Then grinding was<br />

finished with a D8 grinding wheel to an IC measurement<br />

of 9.525 mm (0.025 - 0.035 mm machining tolerance). Illusillustration<br />

2: Element Six PCD disc<br />

All grinding tests were carried out with vitrified-bond<br />

diamond grinding tools of the form 12A2T dimensions<br />

350 x 29 x 300 mm, 10 x 6 mm and grain sizes D8, D15 and<br />

D25. The grinding wheels used were made with Element<br />

Six grit, and the dressing tools were adjusted to the respective<br />

diamond grit size.<br />

The cutting edge of the samples was determined by measuring<br />

the biggest chip of the PCD edge using a Keyence<br />

microscope 2000 with 200 x magnification.<br />

Impact of the cooling lubricant<br />

When grinding the heat-sensitive PCD and brazing area,<br />

the process window can be significantly extended by using<br />

an emulsion as a cooling lubricant. Emulsion has roughly<br />

double the specific thermal capacity compared to oil as<br />

well as four times the thermal conductivity and a 10 times<br />

higher evaporation heat. Preliminary tests with oil were<br />

carried out to quantify the effects of these physical properties<br />

on the grinding process.<br />

illustration 3: Maximum normal (FN) and<br />

tangential (FT) forces when grinding different PCD grades.<br />

Inserts pre-lasered with Neo and finished with D8 wheel<br />

Illustration 4 shows the rim wear on the grinding wheel<br />

per insert. The progress of rim wear is similar and is between<br />

8.0 µm and 21.5 µm per insert. When measured with<br />

regard to grinding forces and rim wear, the PCD grade E<br />

(CMX850) is the easiest to grind. The difficulty of machining<br />

CTB010 inserts (C) with a layer thickness of 0.7 mm<br />

is also evident through the increased wear of 21.5 µm<br />

per insert.<br />

These demonstrated that the PCD grade CTB010 with<br />

a layer thickness of 0.7 mm was the most difficult to machine.<br />

High normal forces lead to de-brazing of the PCD<br />

segment. The cooling performance could be improved by<br />

changing to a 5 % emulsion. The normal forces were markedly<br />

reduced (smaller than 100 N) and de-brazing was<br />

completely eliminated. All tests were carried out using<br />

emulsion as the current investigation compares three PCD<br />

grades with partly different layer thicknesses with uniform<br />

grinding tools and without process adjustment.<br />

Laser pre-machining<br />

In the first test series, only the PCD segments were<br />

roughed by laser to a machining tolerance of 0.04 -<br />

0.05 mm. Then all the inserts were ground using the same<br />

grinding process (identical grinding rim, identical process<br />

parameters). Illustration 3 shows the grinding forces when<br />

grinding five different PCD specifications (designated<br />

A, B, C, D, E), whereby A, B and C are the same material<br />

(CTB010) and only differ with regard to layer thicknesses<br />

of 0.3 mm, 0.5 mm and 0.7 mm. Five inserts of each grade<br />

were ground. The error bar shows the maximum and min i-<br />

mum values measured per grade. It is apparent that the process<br />

forces show a great variation, which depends strongly<br />

on the PCD layer thickness as well as the PCD grade.<br />

illustration 4: Rim wear of D8 grinding wheel depending<br />

on PCD grade, inserts pre-lasered with Neo and<br />

completely ground with D8 grinding layer<br />

no. 2, August <strong>2019</strong><br />


processes<br />

tration 5 shows the normal and tangential forces during<br />

finishing of the A, B and C inserts. Again, the inserts were<br />

finished using identical tools and parameters. The increasing<br />

process forces proportional to the PCD layer thickness<br />

are clearly seen which, together with machining tolerance<br />

and the edge lengths, corresponds to the PCD volume to<br />

be ground. The difference between 0.5 mm (B) and 0.7 mm<br />

(C) is more noticeable on illustration 5 than on illustration<br />

3. The machining tolerance of the pre-grinding was the<br />

same for all samples, only the PCD thickness is different.<br />

Summary<br />

The main influences on PCD grinding are the PCD volume<br />

to be ground (given by thickness, edge length and<br />

machining tolerance of the PCD layer) in combination<br />

with the PCD grade, the diamond grit size of the grinding<br />

tool as well as the cooling lubricant. Therefore, laser<br />

roughing makes dual sense: firstly, the main part of the<br />

PCD is removed with the laser. When roughing, the laser<br />

works independently of the PCD grade, and the removal<br />

rate is 100 x that of grinding.<br />

Other variables that influence performance are the diamond<br />

grain concentration and bond system of the grinding<br />

tool as well as the dressing tool. The investigation confirms<br />

that the use of emulsions for cooling leads to a higher<br />

material removal rate and a higher process stability. The<br />

dia mond grit size D8 selected for the grinding wheel makes<br />

it possible to keep chipping of the cutting edge reliably under<br />

10 µm for the PCD grades CTB010 and CMX850.<br />

Depending on pre-machining strategy, a considerable<br />

economic advantage can be realised. In comparison with<br />

pre-grinding, the following applied for pre-lasering:<br />

• laser roughing reduces the total process time<br />

• laser roughing minimises the consumables (grinding<br />

and dressing layers as well as cooling lubricant)<br />

illustration 5: Maximum normal (FN) and tangential (FT)<br />

forces when finishing roughed PCD inserts with D8 wheel<br />

Illustration 6 shows the layer wear for grades Type A, B<br />

and C for both pre-grinding and finishing. The non-linear<br />

correlation between PCD layer thickness and grinding<br />

layer wear is particularly noticeable during roughing.<br />

In this comparison, the PCD grade C is the most difficult<br />

to grind due to its thickness. Due to the removal of differing<br />

amounts of material, the rim wear between illustrations<br />

4 and 6 is different.<br />

Table 2 serves for quantitative comparison. By lasering,<br />

the main part of the PCD can be removed in under 40<br />

seconds, while pre-grinding takes at least 60 seconds.<br />

lasering +<br />

finishing (D8)<br />

pre-grinding (D25) +<br />

finishing (D8)<br />

roughing lasering pre-grinding (D25)<br />

finishing grinding (D8) grinding (D8)<br />

machining tolerance<br />

(finishing)<br />

0.04 - 0.08 mm 0.035 - 0.04 mm<br />

median cycle time [s] 40 + 150 = 190 60 + 150 =210<br />

grinding tool costs 1 x 2 x<br />

operations 2 2<br />

table 2: Comparison of process strategies<br />

illustration 6: Rim wear for the pre-grinding process with<br />

D25 (blue) and the finishing process with D8 (red)<br />

The project partners<br />

Agathon develops and produces precision grinding machines<br />

for the manufacture of indexable inserts as well as<br />

laser for the pre-machining of super hard materials. The<br />

compact laser Neo with automation makes use of the advantages<br />

of laser pre-machining for increasing batch sizes;<br />

see illustration 7.<br />

40 no. 2, August <strong>2019</strong>

processes<br />

See you soon!<br />

German High Tech<br />

in Metal Working at<br />

20 – 23 November <strong>2019</strong><br />

illustration 7: Laser Neo with automation, high autonomy with<br />

two freely configurable standard palettes for indexable inserts;<br />

the handling is derived from the Agathon grinding machines,<br />

<strong>tooling</strong> and user interface for these are identical<br />

Element Six is part of the De Beers Group and is a<br />

world- leading company for synthetic diamond and tungsten<br />

carbide supermaterials. Element Six produces various<br />

types of PCD for numerous applications. The comprehensive<br />

portfolio stands out due to its consistent high quality<br />

with tight tolerances, even in the case of a large disc<br />

diameter of > 70 mm. The high PCD quality is an important<br />

prerequisite for stable industrial production processes.<br />

This is the reason why complete control of the production<br />

chain from grain to finished disc is vital for Element Six.<br />

Element Six takes a collaborative approach, working alongside<br />

its customers to develop solutions that meet their<br />

needs.<br />

Presented by:<br />

Federal Ministry of Economic Affairs and Energy<br />

In cooperation with:<br />

Association of the German Trade Fair Industry<br />

(AUMA)<br />

Supported by:<br />

German Machine Tool Builders’ Association<br />

(VDW)<br />

Organized by Messe Stuttgart<br />

Tyrolit is one of the leading manufacturers of bonded<br />

high-tech grinding tools for the most varied applications.<br />

In the cutting tool sector Tyrolit offers tailored complete<br />

solutions for customer-specific requirements. The ceramic<br />

bonded grinding tools from Tyrolit have a superior service<br />

life for the present PCD applications thanks to detailed research<br />

in the area of the diamond grains and binding systems<br />

used. Modern manufacturing methods for grinding<br />

tools are a precondition for constantly high quality of the<br />

grinding tools, which is a main contributor to the high<br />

stability of the total process.<br />

further information:<br />

www.agathon.ch / www.e6.com / www.tyrolit.com<br />

www.messe-stuttgart.de/metalex<br />

no. 2, August <strong>2019</strong><br />


processes<br />

Hybrid coating for <strong>tooling</strong><br />

authors: • Tibor Cselle - Andreas Lümkemann, PLATIT AG, Selzach Switzerland<br />

• Mojmir Jilek, PLATIT a.s., Sumperk, Czech Republic<br />

Abstract: Today, the ARC and sputtering processes dominate<br />

the PVD coating market. By combining mul tiple processes<br />

during a deposition process, a hybrid layer is created to combine<br />

the benefits of the different methods.<br />

The feasibility of different procedures is primarily important<br />

for SMEs, (small and medium-sized enterprises) because<br />

they can offer their greatest advantage, flexibility, also in coating<br />

processes. The true use of hybrid technology only applies<br />

when the processes can run simultaneously, not just in succession.<br />

The article presents various industrial practice results for<br />

the use of hybrid layers for cutting.<br />

Hybrid coating for <strong>tooling</strong><br />

No question, the PVD coatings of cutting tools are dominated<br />

by the two main methods: ARCing and Sputtering.<br />

The question is, what the ratio of these methods is in the<br />

industry? The proportion of ARCing is estimated to be<br />

about 80 - 85 %, that of sputtering 10 - 15 %. The remainder<br />

can be assigned to the PECVD procedure.<br />

What are the main advantages and disadvantages of<br />

these two most important methods? Compared to sputtering,<br />

the ARC technology generates a high degree of ionization<br />

with high coating density. It reaches excellent adhesion<br />

with high coating hardness and high productivity.<br />

The sputtering technology generates far fewer droplets and<br />

therefore, smooth coating surfaces.<br />

Figure 1 compares the typical layer surface roughnesses for<br />

the following processes:<br />

● ARCing with lateral and central cathodes (LARC ® :<br />

(Lateral ARC Rotating Cathodes) and CERC ® :<br />

(Central Rotating Cathode),<br />

● sputtering (SCIL ® : Sputtering Coating Induced<br />

by LGD ® : Lateral Glow Discharge), and<br />

● hybrid coating (LACS ® : Lateral Arcing and<br />

Central Sputtering)<br />

For most larger tools (larger than Ø 2 mm), the droplets<br />

can be removed through polishing. There are several<br />

methods available for this [1] , such as: brushing, micro<br />

blasting (dry and wet), drag finishing and stream grinding.<br />

The polishing of micro tools is not possible or very expensive.<br />

Preferably the magnetic finishing can be recommended<br />

for these very tools.<br />

In which cases are we talking about<br />

hybrid coating?<br />

The use of multiple methods during a deposition process<br />

(in a batch) creates a hybrid layer. Why? To exploit and<br />

combine the advantages of different methods.<br />

The realizability of different methods with an installation<br />

is primarily important for SMEs, because they can<br />

only exploit their greatest advantage, flexibility, if they can<br />

change the layers quickly in day-to-day operations and<br />

if they can react in the case of a cyclical change of businesses.<br />

The ability of hybrid plants to realize successive<br />

or simultaneous processes is of fundamental importance.<br />

That’s why we made a distinction between<br />

● sequential and<br />

● simultaneous hybrid systems.<br />

The true technological revolution is the ability to run<br />

the processes simultaneously. The ARC cathodes generate<br />

a highly ionized plasma, which enormously amplifies the<br />

ion density of the sputtered particles. For this solution you<br />

don’t need the expensive HIPIMS electronics (High Performance<br />

Impulse Magnetron Sputtering).<br />

Most clearly, one can see the advantages of hybrid layers<br />

in the doping of ARC layers with sputtered boron [3], [4], [5] .<br />

(Boron is just one example, the hybrid layers are by no<br />

means limited to the use of boron, which has falsely<br />

spread.)<br />

figure 1: Coating surface roughness comparison of<br />

ARC-, sputter- und hybrid-technologies<br />

figure 2:<br />

Hardness & compressive stress at a hybrid coating with boron<br />

42 no. 2, August <strong>2019</strong>

processes<br />

The hybrid layer BorAC ® (AlCrTiN/BN) was simultaneously<br />

deposited from three ARC cathodes and one sputtering<br />

cathode, increasing the sputtering power in steps<br />

(figure 2). By reducing the grain size from 57 nm to 16 nm,<br />

the hardness increases with decreasing residual stress<br />

of the layer. It is not self-evident, on the contrary, it is<br />

surprising and amazing.<br />

First practical results with<br />

hybrid layers produced by LACS ® technology<br />

Do these hybrid coatings also improve tool life for cutting<br />

tools? Compared to conventional standard coatings,<br />

the results are at least equivalent or better (figure 3). Whereby<br />

a state-of-the-art, complex ARC layer (quadlayer ALL4 ® )<br />

can still beat the first versions of the hybrid layer BorAC ® .<br />

● High speed hobbing requires both high hardness and<br />

high toughness. This is the area for which the hybrid<br />

boron layer is already recognized as the best solution<br />

(figure 5) and [3], [4], [6] . Alloyed (expensive) cathodes<br />

with boron (e.g., in AlCrB) can be arced. Once the<br />

optimum alloying ratio has been found using the<br />

sputtering cathode (TiB 2<br />

or B 4<br />

C), the high<br />

productivity layer can go into mass production.<br />

But you will have lost the flexibility.<br />

figure 3:<br />

Using LACS ® -technology at milling in heat treated steel<br />

There are no “veni, vidi, vici” (came, saw and won) in<br />

cutting techno logy. It takes patience to find and develop<br />

the right coatings to their right application fields. Here are<br />

two applications where the results are very promising.<br />

● For hard milling, the high hardness of the layer (with<br />

a lot of silicon, up to 25 %) is decisive (figure 5). The<br />

high toughness (only partly of course, due to the<br />

lower residual stress) becomes relevant when the<br />

same tool (with the same layer) is also used for<br />

other applications. (e.g., figure 4).<br />

figure 5:<br />

Using LACS ® -technology for hobbing<br />

How to find the optimal ratio between chromium, aluminum<br />

and boron: if you must buy the alloyed targets for<br />

every composition, the devel opment becomes expensive<br />

and slow. If you can program the material shares independently<br />

from the unalloyed targets by means of a coating<br />

program [1] , it is much faster and less expensive.<br />

Flexible coating system<br />

for hybrid technology<br />

Why the flexibility? It is vital for an SME. Much more is<br />

possible with a system that has a modular design and can<br />

gradually be expanded with options (figure 6) [1] :<br />

The deposition of all standard layers (which are on the<br />

market today) is already possible in a very economical way<br />

with the 3 ARC cathodes of the eco version. Today, the<br />

DLC option is primarily used to create lubrication coatings<br />

as a top layer.<br />

If the production capacity with the eco machine is no<br />

longer sufficient, the turbo option can deposit 1 - 2 additional<br />

batches per day.<br />

Inserts are usually coated with alumina-based coatings<br />

using the CVD process. The small and medium sized company<br />

cannot afford a CVD system. The OXI option solves<br />

this problem.<br />

figure 4: Using LACS ® -technology<br />

with boron and silicon at hard milling (63 HRC)<br />

For certain tools one needs simple sputtered (smooth)<br />

layers, e.g. TiN, TiCN for taps and deep hole drills.<br />

no. 2, August <strong>2019</strong><br />


processes<br />

figure 6: The options of the hybrid coating unit Pi411<br />

The SCIL ® option offers significant benefits when incorporated<br />

into the LACS ® option and benefits from the high<br />

ionization rate of the LGD of the ARC cathodes (without<br />

droplet formation). This increases the performance of conventional<br />

sputtering layers, such as TiB 2<br />

, WC / C.<br />

The LACS ® option can also be used to make conventional<br />

coatings such as AlCrN. Good adhesion is guaranteed by<br />

the LGD ® . The smooth layers are produced by the simultaneous<br />

SCIL ® cathode with high ionization of the LGD ® .<br />

The LACS ® technology becomes exciting, when including<br />

thermally poorly conductive “doping” from the SCIL ®<br />

cathode, such as boron from TiB 2<br />

or B 4<br />

C and Si from SiC.<br />

Outlook<br />

Technologically the hybrid techno logy promises a lot.<br />

Whether the op por tunities are used, depends on the developers<br />

and their managers, whether they will find the time<br />

and ways to target the right areas of applications.The culmination<br />

of flexibility is the next step that is still in development.<br />

The SCIL cathode is made of carbon and uses<br />

the LACS support to produce hard DLC, also ta:C layers [1] .<br />

These layers extend the application horizon of the plant<br />

further, towards coating of machine components.<br />

References<br />

[1] Compendium, 61st edition<br />

PLATIT AG, Selzach, <strong>2019</strong><br />

[2] Cselle, T., Lümkemann, A., Jilek, M.:<br />

From Start-up to Hybrid Revolution<br />

WerkzeugTechnik, no. 162, August 2017<br />

[3] Lümkemann, A., a. o.:<br />

Introduction of LACS ® Technology<br />

ICMCTF, B1-2-MoA5, San Diego, May/<strong>2019</strong><br />

[4] Zemlicka, R., a. o.:<br />

The New Hybrid LACS ® Technology<br />

PSE, Garmisch-Partenkirchen, September 2018<br />

[5] Tritremmel, C.:<br />

Microstructure and mechanical properties of<br />

nanocrystalline Al-Cr-B-N thin films<br />

Surface & Coatings Technology<br />

213, 2012, page 1-7<br />

[6] Jungblut, F., o. a.:<br />

Beyond HiPIMS - glatte und defektfreie Schichten<br />

für besondere Zerspanungs herausforderungen<br />

VDI-Schneidstoffausschuss, Dortmund, Februar <strong>2019</strong><br />

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

44 no. 2, August <strong>2019</strong>

processes<br />

CERATIZIT has re-imagined turning<br />

Uncompromising turning with complete freedom<br />

High Dynamic Turning, or HDT for short, from<br />

CERATIZIT has turned conventional turning<br />

methods completely upside down. This new turning<br />

technology combined with the dynamic Free-<br />

Turn <strong>tooling</strong>, means that in the future it will be<br />

possible to carry out all traditional turning operations<br />

such as roughing, finishing, contour turning,<br />

face turning and longitudinal turning with<br />

just one tool. HDT is therefore a completely uncompromising<br />

method of turning.<br />

For 100 years, new cutting materials, new chip breakers<br />

and a few new <strong>tooling</strong> systems have been invented to optimize<br />

turning. However, the actual basic turning process<br />

has remained unchanged. Even today, a contour is created<br />

with an indexable insert at a fixed angle to the workpiece.<br />

This has not changed even with the addition of controllable<br />

axes in modern turning-milling centers, machines<br />

which are intended to serve one purpose above all: to manufacture<br />

a component as completely as possible within a<br />

single machine. CERATIZIT has taken advantage of the<br />

systematics of these turning-milling centers and developed<br />

the High Dynamic Turning System. The simple idea behind<br />

HDT: The tool approach and point of contact in the machine<br />

can be varied as opposed to conventional turning.<br />

Utilizing the milling spindle for<br />

360 ° of freedom<br />

Instead of the classic, static position of the insert in the<br />

holder, the milling spindle is now used to produce the corresponding<br />

approach angle to the workpiece. The use of the<br />

spindle drive, in conjunction with the slim, axial tool design<br />

of the FreeTurn tools by CERATIZIT creates a degree of<br />

freedom of 360 ° without the risk of collision, thus providing<br />

unprecedented flexibility. Due to the rotation around<br />

its own tool axis, the cutting-edge change can be done<br />

without interrupting the cutting process. Additionally,<br />

the angle of approach is freely variable at any time and<br />

can even be changed while cutting. This not only enables<br />

flexible machining of almost every workpiece contour, but<br />

also optimum chip breaking, higher feed rates and an increase<br />

in tool life. Depending on the machine capabilities,<br />

the technology can be used functionally in all areas of<br />

turning operations. The approach of the milling spindle<br />

on the Y/Z axis on turning-milling centers is widespread.<br />

As a result, further possibilities can be achieved with HDT<br />

that seemed previously unachievable. For example, cutting<br />

from above and below is possible. Depending on the machining<br />

area and workpiece size, this freedom can be an<br />

important criterion.<br />

FreeTurn inserts with more than<br />

two variable features<br />

In the future of High Dynamic Turning, the static<br />

turning tools of the past will be replaced by dynamic<br />

ones. One such dynamic <strong>tooling</strong> solution is FreeTurn by<br />

CERATIZIT. The defining characteristic of FreeTurn <strong>tooling</strong><br />

is its simple structure. The tool holder, together with its<br />

slim shank and axial concept which optimizes the direction<br />

of the cutting forces into the spindle, form a stable<br />

unit. At the front there is a multi-sided insert, which is<br />

simply screwed in place. The trick: The patent pending<br />

FreeTurn insert can consist of several cutting edges with<br />

different properties. This allows for different angle points,<br />

corner radii or chip breakers - even different coatings and<br />

cutting materials are conceivable. The tool can therefore<br />

be adapted to the machining requirements offering the advantage<br />

of replacing several tools. This in turn leads to significant<br />

savings in tool change times, tool magazine loadouts,<br />

and tools themselves. One outstanding feature is<br />

making components with highly complex contours without<br />

limitation using only one FreeTurn tool. This flexibility<br />

ensures that complex component holding can be quickly<br />

and effectively adapted to the new machining situation.<br />

The future of turning starts now!<br />

With High Dynamic Turning and the FreeTurn tools by<br />

CERATIZIT a new era in turning has arrived. In terms of<br />

efficiency, HDT exceeds the conventional turning process<br />

many times over and, as the experts from CERATIZIT are<br />

convinced, will replace the classic approaches sooner rather<br />

than later. After all, the new turning technology will continue<br />

to open and reveal possibilities in the future to make<br />

turning processes faster and more precise. The future of<br />

turning has just begun with HDT, and CERATIZIT developers<br />

are looking forward to supporting their customers<br />

along this journey together.<br />

The new turning technology combined with the<br />

dynamic FreeTurn <strong>tooling</strong>, means that in the future it will be<br />

possible to carry out all traditional turning operations such as<br />

roughing, finishing, contour turning, face turning<br />

and longitudinal turning with just one tool<br />

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

no. 2, August <strong>2019</strong><br />


processes<br />

Digital transformation is changing the<br />

cutting tool manufacturing industry<br />

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

Fraunhofer Institute for Manufacturing Engineering and Automation<br />

The Digital Transformation within economy<br />

and society is from today’s point of view seen as<br />

the 4th Industrial Revolution (figure 1). Worldwide<br />

manufacturing companies must evaluate the new<br />

digital technologies with respect to their business<br />

model and competitors. In particular the small<br />

and medium-sized enterprises within the cutting<br />

tool manufacturing market lack a precise concept,<br />

which steps need to be taken for the implementation<br />

of digital technologies and which efforts and<br />

benefits can be expected.<br />

The Fraunhofer Institute for Manufacturing Engineering and<br />

Automation IPA in Stuttgart developed a technology roadmap<br />

for small and medium-sized enterprises in the tool<br />

manufacturing market in Germany within a funded project<br />

by the Federal Ministry of Education and Research “Innovationsforum<br />

Zerspanwerkzeuge”. The results were presented<br />

at the International exhibition for metal working<br />

AMB in Stuttgart 2018. Due to the five functional areas<br />

of the digitalisation ( [1] , figure 2) the roadmap for the<br />

tool manufacturing industry is broken down accordingly.<br />

Figure 3 displays for each area the state of the art and the<br />

vision for the next years.<br />

Data as an enabler for the<br />

digital transformation<br />

Data acquisition and data processing build up the foundation<br />

of digital technologies and the digital transformation.<br />

Today in medium sized businesses, a big amount<br />

of data is being already collected and organized in ERP-<br />

Assistance systems to increase efficiency and<br />

compensate the shortage<br />

of specialised staff<br />

Assistance systems include<br />

all technologies, which relieve<br />

the worker from the<br />

exe cution of his tasks. The<br />

assistance systems currently<br />

available on the market<br />

essentially support users<br />

with selective information.<br />

Most of these solutions are<br />

purely expert systems that<br />

are neither mobile nor tailored<br />

to the knowledge and<br />

skills of the individual worker.<br />

In the future, these systems<br />

should be made simpler,<br />

cheaper, more user-friendly<br />

and adapted to the requirements<br />

of the work tasks [1/8] .<br />

When using digital assisfigure<br />

1: Overview of the industrial revolutions and the technological enablers [16]<br />

systems, mainly for the order processing. Data concerning<br />

the whole product life cycle is rarely collected and<br />

used [1/2] . To enable an increasing digitalisation, data acquisition<br />

should be systematically expanded down to product<br />

level. This is made possible by using sensors on the<br />

machine and tool level, by accumulating, processing and<br />

providing data in real-time concerning machine, process<br />

and product. Due to the acquisition and evaluation of<br />

data, conclusions can be drawn concerning quality, tool<br />

life and from this a dynamic tool change can be initiated<br />

even before defective parts are produced [3/4] . In spite of<br />

some implementations of sensors on cutting tools, there is<br />

still a need for intelligent tools, which can combine data<br />

acquisition near the cutting zone by miniaturized sensors<br />

with data evaluation to return the results for control and<br />

adaption of the process parameters [1/5] . The growing use of<br />

sensors in cutting tools and machine tools reveals that in<br />

medium sized companies a high level of implementation<br />

has already been achieved in the area of data acquisition<br />

at the process level leading to an enormous amount of data<br />

and data types to be dealt with. However, this requires<br />

both IT infrastructures and Big Data algorithms, which<br />

can process large amounts of data in real time [6] . For medium<br />

sized companies, scepticism about Big Data applications<br />

is caused by risks related to ensuring data quality and<br />

security, protecting personal data and intellectual property<br />

rights [1/7] . Eventually, many medium sized companies are<br />

unable to see how data-driven business models can create<br />

revenue from their customers.<br />

46 no. 2, August <strong>2019</strong>

processes<br />

tance systems the workers<br />

get optical, acoustic or haptic<br />

signals through systems<br />

such as data glasses, headsets,<br />

RFID-gloves or sensor<br />

bracelets. These interactive<br />

assistance systems (IAS) provide<br />

important information<br />

concerning conditions (e.g.<br />

tool life, wear behaviour)<br />

and processes (e.g. quality)<br />

in real time and enable<br />

workers to make fast and<br />

data based decisions to create<br />

an efficient work flow<br />

despite a higher complexity<br />

of production processes [9] .<br />

Decentral production planning and<br />

digital business models as added value<br />

in the digital transformation<br />

The highest value creation, credited to the digital transformation<br />

is based on the structural change from centralised<br />

enterprise structures to a decentral organisation [13] .<br />

The vision of the transformation process entails the goal<br />

of a service oriented structure, in which every department,<br />

unit, machine and tool together form a system of<br />

autonomous units (Everything as a Service), which offer their<br />

service to the company and the production network [1] . For<br />

SMEs in the <strong>tooling</strong> market, service orienta tion today is<br />

mostly restricted to spare parts supply, logistic services and<br />

technical advice for tools and processes [1/14] . A substanfigure<br />

2: Five functional areas of the digital transformation, according to [1]<br />

Today many engineering apps are developed, which allow<br />

real status and process data from production to be displayed<br />

at any time, anywhere and on any end device. In<br />

tool manufacturing, these applications enable SMEs particularly<br />

to access more IT with low investment costs, e.g.<br />

for the surveillance of capacities, of machines, process<br />

opti misation and control, the detection of critical operating<br />

conditions and quality management [10] .<br />

work pieces to be machined, but will become a central data<br />

source for the efficient control of all necessary production<br />

steps. This will demand a distinct identification of every<br />

tool e.g. by RFID or QR-code to allocate tool specific data<br />

in interaction with the network partners like machines<br />

and work pieces but also tool management systems or<br />

regrinding services [6] .<br />

In the field of machining,<br />

assistance systems are used,<br />

which - with the help of<br />

small apps - assist the worker<br />

in selecting appropriate tools<br />

and suitable cutting parameters<br />

or offer assis tance in<br />

gen erating auto mati cally<br />

the CNC code. These assistance<br />

systems offer above all<br />

to SMEs the possibility to<br />

embed less qualified workers<br />

in production processes.<br />

Digital technologies<br />

in interaction with<br />

production networks<br />

Most decisive for a sustainable<br />

economic success in the<br />

context of digital transformation<br />

is the integration of value creation processes within<br />

the single enterprise itself as well as the cross-company<br />

networking and integration of value creation networks.<br />

Unfortunately, due to a lack of data standards and communication<br />

structures, the degree of networking among SMEs<br />

is currently at a low to very low level [1/2/11/12 . The vision<br />

of the digital transformation in the processing industry<br />

involves an automated, cloud-based exchange of data (internet<br />

of things) between components, planning systems,<br />

cutting tools, manufacturing facilities and measuring<br />

instruments without human intervention.<br />

In the future, the cutting tools in the manufacturing<br />

process will not only be responsible for the quality of the<br />

figure 3: Technology roadmap within the five functional areas<br />

of the digital transformation, according to [17]<br />

no. 2, August <strong>2019</strong><br />


processes<br />

tial integration of custo mer feed back regarding to data<br />

from products and cutting processes cannot be perceived<br />

at present. Tool specific lifecycle data enlarges the business<br />

models of tool manufacturers to IT-based services like payper-use-models<br />

[15] . In these life cycle oriented models the<br />

customer may not own the tools but pays the use per inch<br />

or centimeter. Remanufacturing or regrinding services are<br />

then data based and integrated in the total tool’s life cost<br />

evaluation.<br />

Smart factory - autonomous and self-organised<br />

Autonomy comprises all digital technologies, which enable<br />

an automated data analysis for the self control of the<br />

systems. Partially, some applications are already used for<br />

process and quality control and material supply based on<br />

intelligent self organisational objects. However, currently<br />

autonomy is hardly implemented in any system but part of<br />

the future vision of cyber physical production systems [1] .<br />

Within the cutting technology the cutting tool is seen as<br />

the most important part, which will exchange information<br />

about its status such as tool length, suitable cutting parameters,<br />

wear status or regrinding values presently collected<br />

and exchanged via many systems and subsystems and often<br />

requiring manual intervention [1/3/11] . Despite the maturity<br />

of individual applications, a smart factory, in which<br />

production facilities as well as logistics and supply systems<br />

communicate via internet and organise themselves autonomously,<br />

is still a distant prospect [1] .<br />

Digital transformation - positioning of SMEs<br />

in the cutting tool manufacturing industry<br />

Many digital technologies are available for SMEs today<br />

but are hardly implemented by the tool manufacturing industry<br />

for different reasons. Some companies try to avoid<br />

high investment costs; others are concerned about the<br />

loss of control over data and intellectual property. Nevertheless,<br />

the digital transformation has started and all companies<br />

even SMEs must face these developments to secure<br />

their global competitiveness.<br />

The companies may pass through the digital transformation<br />

process more successfully, provided that the introduction<br />

of digital technologies will take place stepwise depending<br />

on the needs of every single company and with<br />

the support of partners along the value chain.<br />

Literature<br />

[1] Bischoff, J. et al. (2015):<br />

Erschließen der Potenziale der Anwendung von<br />

Industrie 4.0 im Mittelstand<br />

[2] Müller, F. G., Bressner, M., Görzig, D., Röber, T. (2016):<br />

Industrie 4.0: Entwicklungsfelder für den Mittelstand:<br />

Aktuelle Hemmnisse und konkrete Bedarfe<br />

[3] Mapal Dr. Kress (2016):<br />

Fit für Industrie 4.0.<br />

Accessible: https://www.maschinewerkzeug.de/werkzeuge/<br />

uebersicht/artikel/fit-fuer-industrie-4-0-1314991.html<br />

[4] Riehle, L., Gillhuber, A. (2017):<br />

Werkzeughalter initiiert Werkzeugwechsel<br />

Accessible: https://www.maschinenmarkt.vogel.de/<br />

werkzeughalter-initiiert-werkzeugwechsel-a-637042/<br />

(01.08.<strong>2019</strong>)<br />

[5] Zäh, M. (2016):<br />

Industrie 4.0 an der Schnittstelle zwischen<br />

Werkzeug und Maschine<br />

Accessible: https://www.produktion-dienstleistung-arbeit.de/files/<br />

Pdf_Kongress_Vortrag_Zaeh_Koestler.pdf<br />

[6] Permin, o. J.:<br />

Industrie 4.0 - Vernetzte, adaptive Produktion<br />

Accessible: https://www.ipt.fraunhofer.de/<br />

content/dam/ipt/de/documents/Broschueren/<br />

Industrie%2040-Vernetze%20adaptive%20Produktion.pdf<br />

[7] Kroker, M. (<strong>2019</strong>): :<br />

Digitalisierung & Big Data:<br />

Nur 17 Prozent der Unternehmen monetarisieren ihre Daten<br />

Accessible: https://blog.wiwo.de/look-at-it/<strong>2019</strong>/06/03/<br />

digitalisierung-big-data-nur-17-prozent-der-unternehmenmonetarisieren-ihre-daten<br />

[8] Klapper, J. (2018):<br />

Digitale Assistenzsysteme - auch in Ihrer Produktion?<br />

Accessible: https://blog.iao.fraunhofer.de/digitale-assistenzsystemeauch-in-ihrer-produktion/<br />

[9] Kasselmann, S., Willeke, S. (2016):<br />

4.0 READY<br />

Technologie-Kompendium Interaktive Assistenzsysteme<br />

[10] Binzer, J. (2017):<br />

Übersicht über Forschungsprojekte im Bereich Industrie 4.0<br />

VDMA-Forum Industrie 4.0<br />

[11] Hellinger, A., Stumpf, V., Kobsda, C. (2013):<br />

Umsetzungsempfehlungen für das Zukunftsprojekt<br />

Industrie 4.0<br />

[12] Heins, E. (2017):<br />

Industrie 4.0 erfordert intelligente Vernetzung<br />

Accessible: https://www.it-matchmaker.com/news/<br />

industrie-4-0-erfordert-intelligente-vernetzung/<br />

[13] Michel, S. (2015):<br />

Deutscher Mittelstand muss bei Industrie 4.0<br />

aktiver werden<br />

Accessible: https://www.maschinenmarkt.vogel.de/<br />

deutscher-mittelstand-muss-und-kann-bei-industrie-40-<br />

aktiver-werden-a-496110/<br />

[14] Baumbach, M. (2004):<br />

After-Sales-Management im Maschinen- und Anlagenbau<br />

[15] Groß, J. (2017):<br />

Pay-per-use - Disruptives Geschäftsmodell für den<br />

Anlagen- und Maschinenbau?<br />

Accessible: http://hoganlovells-blog.de/2017/09/21/<br />

pay-per-use-disruptives-geschaeftsmodell-fuer-denanlagen-und-maschinenbau/<br />

[16] Deutsches Forschungszentrum für<br />

Künstliche Intelligenz gGmbH DFKI (2011)<br />

[17] Gebhardt, A., Götz, T., Schneider, M., Schumpp, F. (2018):<br />

Industrie 4.0 - Technologieroadmap,<br />

Innovationsforum Zerspanwerkzeuge<br />

further information: www.ipa.fraunhofer.de<br />

48 no. 2, August <strong>2019</strong>

machining center<br />

New standard in universal external<br />

cylindrical grinding<br />

For individual requirements<br />

and large tasks<br />

STUDER continues to cause a sensation with its<br />

universal external cylindrical grinding machines.<br />

After the introduction of the favorit last year, two<br />

new innovations now follow with the S33 and<br />

the S31.<br />

At CIMT in Beijing Fritz Studer AG launched the S33<br />

and the S31 machines, now with four distances between<br />

centers of 400, 650, 1000 and 1600 mm. The distances between<br />

centers of 400 mm and 1600 mm complete the portfolio<br />

for long and short workpieces. Based on the STUDER<br />

T-slide concept, these have an extended X-axis stroke. This<br />

is now 370 mm and enables additional wheelhead variants.<br />

STUDER has redesigned the machine column geometry<br />

and added an innovative column temperature control.<br />

This ensures improved dynamic and thermal stability of<br />

the machines.<br />

The cost and complexity of setup and resetting can now<br />

be significantly reduced. This is made possible by the fixing<br />

of the dressing device on the double T-slot dresser of<br />

the longitudinal slide and by Quick-Set, the STUDER software<br />

for grinding wheel alignment. The standard control<br />

is a Fanuc 0i-TF with the efficient and user-friendly<br />

StuderWIN programming software. Another benefit?<br />

The StuderTechnology computer incorporates the world’s<br />

greatest grinding expertise. With just a little information<br />

StuderTechnology automatically calculates the optimal<br />

grinding parameters in a matter of seconds. The customer<br />

achieves good quality and a quick, stable process at first attempt.<br />

Both machines can be easily automated for series<br />

production thanks to the standardized loader interface.<br />

S31 and S33 with a distance between center of 1000 mm<br />

STUDER S33 - the productive machine<br />

for individual requirements<br />

The S33 has a new wheelhead, which can be equipped<br />

with a motor spindle for external grinding and a high frequency<br />

spindle for internal grinding in different configurations.<br />

Three grinding wheels ensure that the workpiece<br />

is machined even more individually and quickly - complete<br />

machining in a class of its own! The machine has<br />

a B-axis with an automatic 1 ° Hirth coupling. The maximum<br />

workpiece weight is 150 kg.<br />

STUDER S31 - the versatile solution<br />

for large tasks<br />

This machine features StuderGuide® guideways with<br />

damping component in the direction of movement. The<br />

B-axis can optionally be equipped with a direct drive with<br />

a resolution of 0.00005 °. The wheelhead can take up to<br />

three grinding wheels - a combination of external/internal,<br />

up to a maximum of two external or internal grinding<br />

spindles. For high-precision form grinding with the<br />

Fanuc 31i-B control system, the S31 features a workhead<br />

with direct measuring system and the StuderFormHSM<br />

software program.<br />

Advantages at a glance<br />

Distances between centers:<br />

400, 650,1000,1600 mm<br />

StuderGuide ® guideway systems (S31)<br />

- thermal stability thanks to innovative column<br />

temperature control (distances between centers<br />

400 to 1600 mm)<br />

- double T-slot for dressing systems<br />

- numerous grinding head variants<br />

StuderWIN programming software with<br />

StuderTechnology<br />

- both machines can be fully automated<br />

Engine room of the S31<br />

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

no. 2, August <strong>2019</strong><br />


machining center<br />

Two world premier grinding machines<br />

A revolution in grinding productivity….<br />

Curtis Machine Tools Ltd. will<br />

unveil two new innovative grinding<br />

machines for unrivalled productivity<br />

in the field of high precision<br />

grinding.<br />

The world premieres of these revolutionary<br />

machines from CMT will demonstrate<br />

how The Vector Quad and The<br />

Vector Pendulum will bring the grinding<br />

of small parts into a new era of productivity.<br />

They effectively will have double<br />

the output compared to a conventional<br />

grinder simply because they have twice<br />

as many work spindles. The base area of<br />

the quad is unchanged from that of the<br />

Vector twin. The Pendulum is also a compact<br />

grinding machine with twice the capacity<br />

both with a price point that makes<br />

the productivity gains much more attractive<br />

than two machines.<br />

“With this revolution in grinding, users<br />

actually get two machines without having<br />

to pay twice as much,” promises sales<br />

manager Michael Blank of TECNOteam.<br />

The Vector Quad is equipped with four<br />

workpiece spindles and The Vector Pendulum<br />

with two workpiece spindles. This<br />

increases productivity when grinding<br />

large volumes of small parts such as diesel<br />

injectors, turbochargers or hydraulic<br />

parts to previously unimaginable heights.<br />

At the same time, the spark-to-spark time<br />

is reduced because the loading / unloading<br />

of the parts occurs automatically and<br />

in parallel with the grinding process.<br />

Double the output with the same footprint –<br />

world first Vector Quad by CMT: two workpieces ground<br />

simultaneously with automation in parallel giving a spark<br />

to spark time approaching zero<br />

The concept of the Vector Quad is based on the proven<br />

Vector Twin. However, the new machine has an indexing<br />

workhead with four spindles, enabling the outer diameters<br />

or contours to be ground simultaneously on two workpieces<br />

using the same grinding wheel, conventional plunge<br />

grinding is just as possible as is peel grinding. The workpieces<br />

can have a maximum diameter of 45 mm and be<br />

held in either collets or chucks. Whilst two parts are being<br />

ground, either the standard loading system or a robot<br />

loads the two other spindles with the next two workpieces.<br />

CMT will also be unveiling another world premiere at<br />

the EMO exhibition with the Vector Pendulum. Here, the<br />

grinding wheel oscillates between two independent work-<br />

heads, each of which is can be set up for different operations<br />

on the same component. With an inclination of up<br />

to 30 °, the outer diameter and shoulder can be ground<br />

for small parts up to 50 mm in diameter and 150 mm in<br />

length. During oscillation from one workhead to the other,<br />

the grinding wheel can be dressed, giving the ability for<br />

the use of conventional grit grinding wheels, without the<br />

cycle time sacrifice for dressing, giving a low consumable<br />

cost, equally super abrasives can be used as the machine is<br />

capable of spindle speeds in excess of 100 m/s.<br />

EMO <strong>2019</strong>, hall 11, booth D62<br />

further information: www.tecnoteam.de<br />

50 no. 2, August <strong>2019</strong>

machining center<br />

Advanced machine<br />

generation at<br />

EMO <strong>2019</strong><br />

The 3DMP ® (3D Metal Print)<br />

process developed by GEFERTEC<br />

has become the new industry<br />

standard for additive manufacturing<br />

in recent years.<br />

With the support of minority shareholder<br />

EMAG, the arc405, which uses<br />

this method, is available in a new version.<br />

With the increased maturity of<br />

the arc405, the 3DMP ® process will<br />

benefit from expanding its position in<br />

the market and by establishing itself<br />

as supplementary manufacturing process<br />

to conventional processes even<br />

further. The 3DMP ® process is based<br />

on a proven arc welding technology<br />

with wire as raw material, thus, making<br />

it considerably cheaper and faster<br />

than powder-based 3D printing. Also,<br />

wire is available at a much lower price<br />

point for most standard materials.<br />

In addition to the new generation<br />

of machines, the new process<br />

head ARC QM Head with integrated<br />

melt bath control for quality<br />

monitoring will be presented at<br />

the show. This component allows<br />

for the welding process to be monitored,<br />

recorded and documen ted.<br />

All process parameters and a video<br />

image are available for documentation.<br />

By means of this quality control<br />

the stability of the entire manufacturing<br />

process can be demonstrated.<br />

Furthermore, the new arc405 has a<br />

larger build-up space, so that the maxi -<br />

mum component volume increases.<br />

Another advantage of the cooperation<br />

between GEFERTEC and EMAG<br />

Group is their mass production expertise.<br />

As a result, GEFERTEC can meet<br />

the constantly increasing demand for<br />

arc machines while ensuring shorter<br />

delivery times.<br />

View into the<br />

Application-Center<br />

of GEFERTEC, where<br />

the various machines<br />

of the arc series<br />

are in operation<br />

Rough Milling,<br />

Drilling & Slotting<br />

Booth No.:<br />

Hall 5, A13<br />

P M K<br />

TiAl6V4<br />

Short &<br />

Soft Chip<br />

NC Helix Drill<br />

Just four tools can drill dia. from 13-65mm<br />

N<br />

S<br />

H<br />

Reduce processing time!<br />

Reduce your tool invenory!<br />

Serrated<br />

cutting edge<br />

Ramping<br />

Angle<br />

Ø20 Ø25<br />

Ø30<br />

different Ø<br />

by one tool<br />

EMO <strong>2019</strong>, hall 9, booth K03<br />

further information: www.gefertec.de<br />


International Corp.<br />

TEL: +886-(0)4-22605352<br />

FAX: +886-(0)4-22608765<br />

E-mail: trade@jimmore.com.tw<br />


machining center<br />

KERN Micro-Highest precision<br />

while milling around the clock<br />

Company improves its overall performance<br />

Precision, reliability and<br />

economic efficiency have the<br />

highest priority for Buschor<br />

Praezisionsmechanik AG. With<br />

two Kern Micro five-axis machining<br />

centers, the Swiss company<br />

has improved its overall<br />

performance.<br />

Werner Buschor leaves nothing to<br />

chance. In order to manufacture the<br />

high-precision parts which he supplies<br />

to the optical and aerospace industries,<br />

the Swiss medium-sized company<br />

has structured the entire machining<br />

process chain with incredibly<br />

small tolerances. The entire production<br />

area is air-conditioned, raw material<br />

is always annealed once again<br />

before the machining process begins.<br />

The manufactured components are<br />

checked by Werner Buschor and his<br />

team on a high-precision Leitz measuring<br />

machine.<br />

Finally, the finished parts are always<br />

being directly delivered to the customers<br />

- this ensures that they are not<br />

damaged during transportation. This<br />

whole process underlines the “joy of<br />

precision” - which Buschor has also<br />

included in his company’s logo.<br />

Werner Buschor has continuously<br />

expanded and improved his process<br />

Intensive cooperation: Werner Buschor (left)<br />

and Kern sales technician Stephan Zeller<br />

regularly exchange ideas about<br />

optimization possibilities<br />

picture: KERN Microtechnik<br />

chain ever since he founded his company,<br />

Buschor Praezisionsmechanik<br />

AG, in Au in Eastern Switzerland in<br />

1989. About three years ago, the<br />

trained polymechanic needed and also<br />

wanted to increase the process relia<br />

bility of production once again.<br />

Parts with tolerances in the microme<br />

ter range were to be produced, auto -<br />

matically and unmanned on nightand<br />

weekendshifts. Looking for a machine<br />

which could fulfill his needs,<br />

he came across the Micro from Kern.<br />

After an intensive and inspiring exchange<br />

with Kern sales technician<br />

Stephan Zeller and visits to Eschenlohe<br />

in Upper Bavaria, Germany, he<br />

invested in the first machine.<br />

Buschor explains: “The Kern<br />

Micro is the first milling center that<br />

can stand up to our measuring machine,<br />

which we had purchased two<br />

years earlier. The measuring machine<br />

has a measurement uncertainty of<br />

half a thousandth of a millimeter<br />

and the Kern Micro offers a positioning<br />

accuracy of half a thousandth of<br />

a millimeter. The first Kern Micro was<br />

immediately connected to a 3R automation<br />

system, with the possibility<br />

of adding another machine. The large<br />

tool magazine with 186 tools and the<br />

repeatability of the Kern Micro are<br />

ideal for automatic production.<br />

“Finally, we can manufacture workpieces<br />

that require the highest precision<br />

unmanned”, explains the company<br />

owner and adds: “Only this way<br />

we can secure our profitability at our<br />

high-wage location. The empty job<br />

market is also forcing us to produce<br />

with full automation.<br />

“Since we no longer have to stand<br />

at the machine to produce good parts,<br />

we have time to take care of the other<br />

important things. The other five-axis<br />

milling centers already in place are all<br />

automated but do not achieve the necessary<br />

process stability in unmanned<br />

operation,” says Buschor.<br />

The tool changer is in between the<br />

two machines and provides the tools<br />

for both machines<br />

Clear and easy to access: the Kern Micro tool<br />

magazine offers space for 186 tools as<br />

standard, allowing automatic production<br />

picture: KERN Microtechnik<br />

“It is a real pleasure to be able to<br />

produce high-precision parts with<br />

such a machine. When we measure,<br />

it’s always amazing to see how precise<br />

the machine works.”<br />

The thermal stability of the machine<br />

is a decisive factor for this high<br />

process reliability. Kern sales engineer<br />

Stephan Zeller explains: “With our<br />

smart cooling management system,<br />

we ensure that the temperature of<br />

our structural components in our machines<br />

remains constant with a max.<br />

deviation of 0.2 C.”<br />

For the developers at the machine<br />

manufacturer in Eschenlohe, Germany,<br />

it is very important to install<br />

many elements vibration-decoupled<br />

or vibration-damped. The patented<br />

52 no. 2, August <strong>2019</strong>

machining center<br />

light-metal axis structure and the<br />

Kern software for volumetric compensation<br />

bring the performance of this<br />

high-tech machine to an unmatched<br />

level. Another advantage for Buschor<br />

is the compact design of the Kern<br />

milling center. According to Buschor,<br />

there was not much space left in 2015<br />

when the first Kern Micro arrived:<br />

“The ratio of installation area to part<br />

size is huge; the Kern Micro allows<br />

part sizes of up to Ø 350 mm with a<br />

total weight of 50 kg and achieves this<br />

on approx. 4 m 2 .”<br />

It was a surprise for Buschor how<br />

much accessibility the machine provides<br />

despite of the compact design.<br />

“You always have a perfect overview<br />

over tools, parts and the whole machining<br />

process”, explains Buschor.<br />

For Werner Buschor, the space-saving<br />

design has already paid off. When<br />

the new orders did not stop coming<br />

in, he installed a second Kern Micro<br />

in 2017. Now, the tool changer is in<br />

between the two machines and provides<br />

the tools for both machines. The<br />

purchase of a third Micro is already<br />

planned.<br />

The high process reliability is not<br />

only important in unmanned operation.<br />

Since Buschor also manufactures<br />

prototypes with batch sizes of only<br />

20 and up to 20,000 units, the two<br />

Kern machines are frequently used for<br />

these orders. “Especially with complex<br />

parts, these parts were always<br />

very challenging,” says Buschor. They<br />

produced a test part, measured it,<br />

made corrections, produced another<br />

part, measured it and often corrected<br />

it again. “With the Kern Micro, the<br />

first part already fits, which makes us<br />

fast and flexible.”<br />

Support is key<br />

The entrepreneur’s enthusiasm is<br />

also due to the great support KERN<br />

Microtechnik GmbH provides. Whenever<br />

there are problems, Kern offers<br />

outstanding support - for the machine<br />

itself as well as for the complete manu -<br />

facturing process.<br />

One of Kern’s advantages is that<br />

Kern has - in addition to the mechanical<br />

engineering plant - also its own<br />

parts production plant in Murnau,<br />

The tool changer and the 3R automation<br />

system are placed between<br />

the two Kern machines<br />

picture: KERN Microtechnik<br />

Upper Bavaria. Of course, this plant<br />

is well equipped with Kern machines.<br />

The technicians working on these machines<br />

are always up to date with the<br />

latest application technology and are<br />

available to assist customers with specific<br />

milling tasks.<br />

With his<br />

motto, “The joy<br />

of precision”,<br />

Buschor meets<br />

like-minded<br />

people at Kern.<br />

Stephan Zeller,<br />

a trained master<br />

precision<br />

mechanic himself,<br />

describes<br />

the relation<br />

with Buschor:<br />

“It makes us<br />

very proud that<br />

we are able to<br />

support the famous<br />

‘Swiss<br />

precision’ to<br />

such a large<br />

extent”.<br />

Maximum precision: Werner Buschor and<br />

his team inspect the components on a<br />

high-precision measuring machine<br />

picture: KERN Microtechnik<br />

In order to provide these services<br />

to customers in Switzerland, Kern also<br />

has a service location near Zuerich.<br />

From the Swiss location, service technicians<br />

with know-how and spare<br />

parts provide solutions and assistance.<br />

Optical industry are the speciality of Buschor Praezisionstechnik AG<br />

picture: KERN Microtechnik<br />

further information: www.kern-microtechnik.com<br />

no. 2, August <strong>2019</strong><br />


machining center<br />

Automation, digitalisation and<br />

full machine power<br />

The four machine models exhibited<br />

at the Hermle booth at<br />

EMO represent Hermle’s portfolio<br />

of products and services.<br />

The 5-axes machining center C 42 U MT<br />

dynamic, which combines the milling and<br />

turning technologies in a unique manner<br />

face initiated by VDW, Hermle is also<br />

interlinked while at the EMO and<br />

shows the connection with a C 32 U<br />

dynamic. The area of generative manufacturing,<br />

with components manufactured<br />

using MPA technology, also<br />

has its own area in the 560 m 2 exhibition<br />

booth.<br />

The C 42 U MT dynamic from the<br />


com bines the technologies milling<br />

and turning in a unique manner. The<br />

manufacture of a motor casing made<br />

of 1.2312 steel, Ø 600 mm, intended<br />

for aerospace engineering, demonstrates<br />

the technologies in a single<br />

clam ping. Trochoidal turning is used<br />

as well and demonstrates the huge<br />

benefits of combining both processes<br />

in a single clamping.<br />

With the C 32 U dynamic, Hermle<br />

presents another 5-axes machining<br />

center from the HIGH-PERFORMANCE-<br />

LINE series. Here, the focus is on<br />

spindle power. The demo machining<br />

“Heavy-duty machining” impressively<br />

shows the superior performance. With<br />

a maximum speed of 15.000 rpm,<br />

42 kW power and a torque of 148 NM,<br />

the spindle in combination with the<br />

highly rigid design of the C 32 in<br />

mineral casting technology shows the<br />

possibilities of intelligent milling strategies<br />

combined with state-of-the-art<br />

tool technology.<br />

The machining of a motor casing<br />

on a C 42 U MT (Mill/Turn)<br />

The Automation sector, which at<br />

Hermle’s currently accounts for approximatly<br />

30 % of the machines delivered,<br />

is growing steadily: The forecast<br />

for the next few years sees an increase<br />

of up to 50 % in machines delivered<br />

with automation.<br />

Hermle presents two different automation<br />

solutions at the EMO: The<br />

hand ling system HS flex adapted to a<br />

5-axis machining center C 400 of the<br />

PERFORMANCE-LINE series. On a mo du -<br />

lar basis, the HS flex can be equipped<br />

with several storage modules and can<br />

be extended by a second stage to form<br />

a multi-pallet system. When combined<br />

with the Hermle Automation Control<br />

System (HACS), HS flex offers enhanced<br />

flexibility and operator comfort.<br />

EMO <strong>2019</strong>, hall 12, booth C36<br />

They are supplemented by the special<br />

exhibition ‘Digital Components’<br />

illustrating the three sections “Digital<br />

Production”, “Digital Operation”<br />

and “Digital Service”. They provide a<br />

solid foundation for intelligent order<br />

management, transparent machining<br />

processes, smart machine turning, paperless<br />

shop floor, and sophisticated<br />

technology cycles - the milestones for<br />

the path to Smart Factory and Industry<br />

4.0. With its individually configurable<br />

home screen and the new Navigator interface,<br />

Hermle guarantees user-friend -<br />

liness and improved use of the touch<br />

screen. With UMATI, the new interfurther<br />

information: www.hermle.de<br />

Connected to your needs<br />

The GF Division’s customercentric<br />

presence will bring together<br />

a vast range of advanced<br />

and intelligent solutions to take<br />

manufacturers’ processes to the<br />

next level of productivity.<br />

Take a sneak peek into the future by<br />

visiting GF Machining Solutions. With<br />

its customer-centric theme, “Connected<br />

to your needs,” the GF Division<br />

will bring together a vast range of<br />

ad vanced and intelligent solutions<br />

poised to take manufacturers’ processes<br />

to the next level of productivity.<br />

These solutions go beyond GF<br />

Machining Solutions’ renowned<br />

Milling and Electrical Discharge<br />

Machining (EDM) expertise to include<br />

new technologies such as Laser texturing,<br />

micromachining and Additive<br />

Manufacturing (AM), and a continuum<br />

of Customer Services as well as<br />

productivity-enhancing software and<br />

connectivity solutions.<br />

Among the leading-edge solutions<br />

GF Machining Solutions’ EMO <strong>2019</strong><br />

guests will encounter:<br />

Digital products to advance users’<br />

Industry 4.0 readiness, including the<br />

Open Platform Communications (OPC)<br />

Unified Architecture (UA) protocol.<br />

A common machine communication<br />

language across all GF Machining<br />

Solu tions machines, technologies<br />

and services, the OPC UA collects and,<br />

through the new rConnect Dashboard,<br />

54 no. 2, August <strong>2019</strong>

machining center<br />

makes accessible a wide range of data<br />

that manufacturers can use to better<br />

analyze and fine-tune their processes.<br />

Thanks to the rConnect digital services<br />

platform’s connectivity, users<br />

have instant access to expert online<br />

support.<br />

The AgieCharmilles CUT AM 500,<br />

a horizontal, fast wire EDM solution<br />

that makes it easy to separate<br />

additively ma nu factured metal<br />

parts from the build plate while<br />

maintaining geome trical ac curacy<br />

and ensuring assembly rea di ness.<br />

This machine is the perfect complement<br />

to GF Machining Solutions’<br />

and 3D Systems’ scalable, workflowoptimized<br />

DMP Factory 500 and DMP<br />

Flex 350 3D metal printing solutions.<br />

The Mikron MILL S 400 U with the<br />

HEIDENHAIN TNC 640 contouring<br />

control represents the Mikron MILL S<br />

range of high-speed Milling solutions<br />

at EMO. This range boasts Automated<br />

Machine Calibration (AMC) enabling<br />

users to calibrate five-axis models at<br />

any time to achieve greater machining<br />

precision and Original Manufacturing<br />

Calibration (OMC) ensuring<br />

higher three-axis machine precision<br />

straight from the factory.<br />

The AgieCharmilles CUT P 550 PRO<br />

with a groundbreaking and superbly<br />

easy-to-use new human-machine interface<br />

(HMI) to be launched in 2020.<br />

Whether the machine operator is used<br />

to working with the Vision interface<br />

or is accustomed to ISO programming,<br />

the new object-oriented HMI represents<br />

an unprecedented alternative.<br />

The DMP Flex 350, a robust, flexible<br />

metal 3D printing solution from<br />

GF Machining Solutions and 3D Systems.<br />

With its improved print productivity,<br />

this machine can drive users’<br />

time to market with reduced cost of<br />

operation.<br />

EMO <strong>2019</strong>, hall 27, booth B26<br />

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

The sequel to a successful event concept<br />

What does the automotive<br />

future hold? This question is<br />

one way you could briefly summarize<br />

the motto of the EMAG<br />

Group’s <strong>2019</strong> Technology Forum<br />

held at its headquarters this<br />

May.<br />

The Technology Forum is traditionally<br />

held in the same year as the EMO<br />

trade show and offers visitors a preview<br />

of what EMAG will present at the<br />

EMO. This year, the event provided<br />

visitors with a comprehensive outlook<br />

on what suppliers and manufacturers<br />

will have to do to be prepared for the<br />

changes in the coming decade.<br />

High-caliber research experts reported<br />

on how electromobility and digitalization<br />

will change mobility. Visitors<br />

were also able to see, first-hand,<br />

the latest manufacturing systems and<br />

machines available at a number of<br />

themed booths. According to the visitor<br />

survey conducted at the conclusion<br />

of the event, this concept really<br />

hit the mark. That is why EMAG is<br />

hosting an “event sequel” at the EMO<br />

exhibition in Hanover, Germany.<br />

Solving problems requires the right<br />

tools and expertise - one is useless<br />

without the other. That is why EMAG<br />

presents both at the EMAG booth at<br />

the EMO in Hanover: The latest machine<br />

tools and automation solutions,<br />

which will celebrate<br />

their world premiere<br />

at the EMO.<br />

EMAG will also<br />

demonstrate the expertise<br />

necessary to<br />

combine these machines<br />

and the variety<br />

of technologies<br />

available within the<br />

EMAG Group’s umbrella<br />

of companies,<br />

to create the most efficient<br />

manufacturing<br />

solutions. In the “themed areas,”<br />

which will be entirely dedicated to<br />

the production of specific groups of<br />

components, visitors will find answers<br />

to their specific production questions<br />

and the matching manufacturing solution.<br />

These solutions range from<br />

single-machines all the way to fully<br />

automatic manufacturing lines that<br />

are delivered to customers turnkey<br />

and ready for operation - including<br />

the entire development process.<br />

E-mobility:<br />

is everything going to change?<br />

One of the mega topics at the EMAG<br />

Group’s Technology Forum was e-mobility<br />

and its implications for manufacturers<br />

and suppliers. Visitors gained<br />

the following insight: Yes, changes<br />

are coming, but at a much slower pace<br />

than expected. So, should we carry on<br />

as usual? No, this is the perfect time to<br />

position yourself and your company<br />

for the future. Which components will<br />

be needed? What manufacturing solutions<br />

are available? What investments<br />

should I expect? EMO visitors will find<br />

answers to these questions, and more<br />

at the EMAG Group’s booth. You will<br />

find not only new components, but<br />

things such as differentials or brake<br />

discs that will still be required, regardless<br />

of the drive technology implemented.<br />

EMAG will be showcasing<br />

the production solutions for not only<br />

these components, but many more<br />

revealing major insights from the<br />

<strong>2019</strong> Technology Forum.<br />

EMO <strong>2019</strong>, hall 17, booth C29<br />

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

no. 2, August <strong>2019</strong><br />


machining center<br />

Rugged and reliable machines for<br />

high production manufacturing<br />

JTEKT Toyoda Corporation<br />

will showcase the FH500J highspeed<br />

horizontal machining center<br />

and Takisawa Taiwan NEX-<br />

105 horizontal linear turning<br />

center at EMO Hannover <strong>2019</strong>.<br />

Toyoda meets the growing demand<br />

for producing components with high<br />

metal removal rates, short cycle times,<br />

and good surface finishes at a com-<br />

FH500J high-speed<br />

horizontal machining center<br />

The TH3-MT continues to offer the<br />

key benefits of TH series solutions:<br />

high dynamics (up to 40 m/min rapid<br />

feed with 3 m/s 2 accelerations) and interoperability<br />

with the next generapeti<br />

tive price. Toyoda’s FH500J horizontal<br />

machining center is designed<br />

for speed and production reliability –<br />

featuring a 15,000 RPM, 50 HP<br />

(37 kW), 303 Nm (223 ft-lb) high ac cele<br />

ration spindle. This 40-taper spindle<br />

is designed with four ceramic bearings<br />

at the front of the spindle for unrivaled<br />

rigidity and reduced vibration.<br />

Its patented hydraulic preload system<br />

brings your spindle up to 10,000 RPM<br />

less than 1 s without spindle warm<br />

up. This machine is equipped with a<br />

direct drive B-axis table featuring an<br />

index time (90 °) of 0.5 s. The FH500J<br />

machining center - with the spindle<br />

design, preload system, and high<br />

torque features - allows machine shops<br />

to take advantage of more aggressive<br />

machining and high volume machining<br />

in a compact footprint. Less than<br />

2 % of FH500J spindles have needed<br />

replacement.<br />

In alliance with Takisawa Taiwan,<br />

JTEKT Toyoda will also be displaying<br />

the NEX-105 turning center at the<br />

show. The NEX-105 is a compact solution<br />

capable of mass producing small<br />

complex parts, offering spindle speed<br />

up to 6,000 RPM and fast indexing capabilities<br />

on its linear roller bearing<br />

guideway. This 6” chuck size machine<br />

will be running live cutting demonstrations<br />

throughout the show, featuring<br />

a maximum swing of 15.7”<br />

(398 mm), and a maximum turning<br />

diameter of 6.7” (170 mm).<br />

EMO <strong>2019</strong>, hall 27, booth D86<br />

NEX-105 turning center<br />

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

High-productivity multitasking<br />

machining centers at the EMO fair<br />

Productivity, increased autonomy<br />

and improved accuracy.<br />

These are the axes of JUARISTI’s<br />

innovation strategy, which in recent<br />

months has led to the de velopment<br />

of the new TH3-MT Multifunction<br />

Center, optimised for<br />

highly reliable boring, milling<br />

and turning operations, and the<br />

new ACD7 and ACD8 universal<br />

heads, designed for maximum<br />

precision 5-axis machining.<br />

For JUARISTI, a company specialising<br />

in the design and manufacture<br />

of premium machining solutions, the<br />

EMO <strong>2019</strong> trade fair will be a huge<br />

opportunity to present the most disruptive<br />

developments of the last year.<br />

On this occasion, the company will<br />

be exhibiting the advantages of the<br />

new TH3-MT Multitasking Machining<br />

Center, its commitment to fulfil<br />

the needs of customers who demand<br />

a machine capable of performing multiple<br />

milling and turning operations<br />

with greater productivity and precise<br />

results, and the new range of 5-axis<br />

universal heads.<br />

The new machining center is a new<br />

development in the TH series, the<br />

JUARISTI 5-axis Multifunctional Centers,<br />

which this time includes a milling<br />

and turning table and a special<br />

milling head with an optimised design<br />

for milling and turning operations.<br />

The center includes a comprehensive<br />

automation package and has been com -<br />

pletely redesigned to improve ergonomics,<br />

extend service life and optimise<br />

swarf and cutting fluid management.<br />

56 no. 2, August <strong>2019</strong>

machining center<br />

tion high feed and high swarf removal<br />

tools. Thanks to its symmetrical design<br />

with a column-centerd head and<br />

four guides (two front and two rear),<br />

it offers unbeatable precision, thermal<br />

stability and high cutting power.<br />

The major breakthrough has been<br />

the introduction of a new special<br />

head for turning and a turning table.<br />

JUARISTI’s new head, dubbed the ACD8,<br />

is a universal model that allows 5-axis<br />

machining and reaches rotation speeds<br />

of up to 8,000 rpm, with high power<br />

(60 kW) and spindle torque (1,600 Nm).<br />

The milling and turning table included<br />

in the machine will have a<br />

Ø 1,600 chuck diameter (options up<br />

to Ø 2,000) with a 400 rpm maximum<br />

speed and a five tonnes maximum<br />

part capacity in turning and<br />

ten tonnes in milling. Rotation speeds<br />

reach 400 rpm.<br />

The new machine features multiple<br />

automated systems that can be adapted<br />

to customer requirements, including<br />

a quick-change matrix tool changer<br />

with the capacity for up to 200 tools<br />

and an FMS multi-pallet system.<br />

Finally, the TH3-MT has gone<br />

through an extensive redesign process,<br />

achieving a more stylish and ergonomic<br />

ensemble. The new design<br />

achieves a more compact layout for<br />

better floor space usage. Plus, it optimises<br />

the swarf and cutting-fluid collection<br />

system, improving the solution’s<br />

autonomy and avoiding unproductive<br />

downtimes due to manual<br />

cleaning.<br />

EMO <strong>2019</strong>, hall 13, booth B03<br />

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

New from the ground up<br />

WALTER showed two new<br />

HELITRONIC models at this<br />

year’s Grinding Symposium of<br />

the UNITED GRINDING Group<br />

in Thun, Switzerland: the HELI-<br />


grinding and eroding machine.<br />

WALTER’s latest machines feature<br />

a grinding wheel/electrode changer<br />

and extended traverse, and can<br />

now machine tools up to 380 mm in<br />

POWER 400<br />

wheelchanger<br />

length, surpassing the previous limit<br />

of 280 mm. But the two machines<br />

offer more than just longer workpiece<br />

lengths. WALTER engineers<br />

completely redesigned the HELI-<br />


POWER DIAMOND multi-functional<br />

machines.<br />

For example, the base of both machines<br />

was completely remodelled.<br />

The new, more rigid machine bed ensures<br />

even better damping behaviour<br />

which in turn facilitates greater precision<br />

and higher surface quality. The<br />

C-axis of the standard version of both<br />

new machines is driven by a worm<br />

drive. A low-maintenance and extremely<br />

accurate torque motor is also<br />

available as an optional feature.<br />

The engineers also used the pneumatically<br />

driven steady rests and tailstocks<br />

from the HELITRONIC VISION<br />

series. This means that the steady<br />

rests and tailstocks are less prone<br />

to leaks, require less maintenance<br />

and are much cleaner. They also absorb<br />

less heat than components that<br />

use hydraulic oil, thus ensuring even<br />

greater precision.<br />

Like all “Two-in-one” machines<br />

from WALTER, the new HELITRONIC<br />

POWER DIAMOND 400 also uses FINE<br />

PULSE TECHNOLOGY. Unlike the<br />

previous models, the HELITRONIC<br />


wheel-electrodechanger<br />

POWER DIAMOND 400 and<br />

HELITRONIC POWER 400 machines<br />

can be automated with a top loader<br />

for up to 500 tools, a robot loader for<br />

up to 7,500 tools or the robot loader<br />

25. The robot loader 25, which has a<br />

carrying capacity of 25 kg including<br />

grippers, was previously only available<br />

as an option for HELITRONIC<br />

VISION machines. Both machines<br />


grinding and eroding software.<br />

information: www.walter-machines.com<br />

no. 2, August <strong>2019</strong><br />


machining center<br />

Time advantage of up to 50 %<br />

First worldwide 2-spindle hobbing machine with<br />

integrated chamfer unit for E-transmission-shafts<br />

has a cycle time advantage of up to 50 %<br />

Electric drives pose new<br />

challenges for the conventional<br />

method of manufacturing gearbox<br />

parts, which is partially due<br />

to the elimination of the combustion<br />

engine as well as the<br />

higher operating speeds.<br />

These demands on quality not only<br />

apply to gear hobbing - they equally<br />

apply to secondary processes such as<br />

chamfering. Deforming methods used<br />

up till now, such as roll chamfering<br />

however, are unsuitable for this. Existing<br />

cutting processes are implemented<br />

as a separate consecutive operation<br />

with reclamping after the hobbing resul<br />

ting in quality losses. For this reason,<br />

Felsomat GmbH & Co. KG has<br />

integrated its own process - Chamfer-<br />

Skiving - in a 2-spindle hobbing machine,<br />

with a tail stock for shaft parts,<br />

so that the chamfer process can run<br />

simultaneous to the hobbing, without<br />

reclamping, resulting in a high<br />

quality chamfer. Thanks to this special<br />

configuration, chamfer matching<br />

the drawing specification are possible<br />

even with space restrictions. The innovative<br />

system concept will be presented<br />

at the EMO <strong>2019</strong> in Hanover.<br />

“The quality requirements for hobbing<br />

in an E-transmission have increased,<br />

due to considerably higher<br />

speeds compared to combustion engines”,<br />

reports Johan Thijssen, Technology<br />

Manager at Felsomat GmbH &<br />

Co. KG. “On top of that, also a greater<br />

diversity in electric motors and their<br />

speed reducers is to be expected in<br />

the coming years, so that short setup<br />

times with a high repeatability are essential.”<br />

In regards to the production<br />

processes, this means that even secondary<br />

processes such as gear chamfering<br />

and deburring gain importance, and<br />

these must be optimised in regard to<br />

the final quality and machining time.<br />

Greater complications in addition<br />

arise with the E-transmission shafts,<br />

whereby<br />

the tool<br />

has less<br />

space<br />

available<br />

due to the<br />

compact<br />

design:<br />

“Unlike<br />

conventional<br />

gear<br />

wheels, the<br />

tooth root<br />

for E-transmission<br />

shafts lies<br />

very close<br />

to the shaft<br />

itself”,<br />

explains<br />

Thijssen.<br />

“As a consequence,<br />

they<br />

increase<br />

the space<br />

restriction<br />

and reduce<br />

the tool’s<br />

freedom<br />

of movement.”<br />

In order to enable high-quality chamfering simultaneous to the<br />

hobbing time even with space restrictions, Felsomat GmbH & Co. KG<br />

has developed a machining system in which, for the first time,<br />

a ChamferSkiving unit is integrated into a 2-spindle hobbing unit,<br />

eliminating cycle time losses<br />

Nevertheless, in order to enable<br />

high-quality chamfering simultane<br />

ous to hobbing, even in the case of<br />

space restrictions, Felsomat GmbH &<br />

Co. KG has developed a system in<br />

which a chamfering unit has been inte<br />

grated into a 2-spindle hobbing machine<br />

for the first time. Cycle time<br />

los ses are thereby avoided. For the end<br />

user it is also very important to be<br />

able to handle an increasing variety of<br />

parts at high production rates.<br />

The 2-spindle concept<br />

guarantees high productivity<br />

with no idle times<br />

The process variety in machining is<br />

enabled by the 2-spindle design: the<br />

separate operating tool heads allow<br />

the workpiece to be hobbed on one<br />

spindle, while in a secondary process,<br />

for example, the chamfering is done<br />

on the other spindle simultaneous to<br />

hobbing process. The spindles thereby<br />

rotate automatically into and out<br />

of the hobbing area. Different process<br />

variants between hobbing and chamfering<br />

can be realised in one clamping<br />

depending on the finishing condition<br />

of the gear. “For example, a shaft<br />

is clamped and first rough hobbed. It<br />

then leaves the hobbing area and is<br />

chamfered before being rotated back<br />

into the hobbing area. A second hob<br />

cut can be made to eliminate secondary<br />

burrs in the gear flank. This second<br />

cut can also be a gear finish hobbing<br />

pass”, Thijssen explains.<br />

The chamfering process itself was<br />

also optimised, to enable a higher production<br />

quality. The chamfer skiving<br />

58 no. 2, August <strong>2019</strong>

machining center<br />

developed for this purpose is based on<br />

the principle of gear skiving. Thanks<br />

to the split of the machining into two<br />

tools for the acute and obtuse tooth<br />

edges as well as the spatial position<br />

of the tools, better chamfering results<br />

are possible, even if there are space<br />

restrictions. This makes it easier to<br />

achieve even difficult geometries on<br />

the workpiece and the desired chamfers<br />

can be produced according to the<br />

drawing specifications.<br />

Space-saving and easy to set up<br />

Despite the compact design of only<br />

7 m² installation space, the system<br />

concept is flexible and highly productive.<br />

An advantage here is the wide<br />

speed range achieved by the hob spindle,<br />

which has a power of up to 27 kW.<br />

In this way, all hob cutter types from<br />

PM (powder metallurgy) to carbide<br />

can be used with just one drive at<br />

cutting speeds of up to 1,000 m/min.<br />

This versatility in combination with<br />

the 2-spindle concept enables the<br />

system to hob and chamfer shafts<br />

up to 300 mm in length with high<br />

accuracy and according to drawing<br />

specifications.<br />

The especially developed<br />

ChamferSkiving as well as the<br />

split of the machining into two tools –<br />

for the left and right tooth edges,<br />

respectively - and the spatial position<br />

of the tools, enable better chamfering<br />

results, even if there are space restrictions<br />

(source: Felsomat GmbH Co. KG)<br />

“Since a wide variety of transmission<br />

ratios will occur in the course<br />

of new electric motor variants, it can<br />

be assumed that due to the frequent<br />

change of variants, it will also be necessary<br />

to do set ups during the shift”,<br />

Thijssen explains. “This is why we<br />

paid attention to very short setup<br />

times when developing this system.”<br />

On top of that, loading and unloading<br />

takes place simultaneous to the<br />

hobbing time, and the system can<br />

also be integrated into a production<br />

line as a module. Since the 2-spindle<br />

design allows the workpieces to be<br />

machined more quickly, cycle times<br />

can be reduced by up to 50 % compared<br />

to a 1-spindle design. This has a<br />

positive effect on the production time<br />

of the entire line.<br />

The new FHC 100 S hobbing<br />

machine with integrated<br />

chamfering process will be<br />

presented at<br />

EMO <strong>2019</strong> hall 26, booth C109<br />

further information: www.felsomat.de<br />

dihw, <strong>hp</strong> <strong>tooling</strong> & WiN<br />

Your winning team.<br />

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Dr. Harnisch Verlags GmbH · · Blumenstr. 15 15 · · D-90402 Nuremberg · Tel: · Tel: +49 +49 (0)911 2018 2018 0 · 0 Fax: · Fax: +49 +49 (0)911 (0)911 2018 2018 100 100 · · info@harnisch.com · · www.harnisch.com

components<br />

NUM helps Taiwanese machine tool company<br />

to automate production of involute and<br />

cycloidal gears for robotics<br />

NUM is helping the Taiwanese<br />

machine tool company Chien<br />

Wei Precise Technology to develop<br />

innovative CNC grinding<br />

machines for manufacturing<br />

spe cia list gears used in robotics<br />

applications.<br />

Based entirely on NUM’s latest-generation<br />

Flexium+ 68 CNC platform,<br />

Chien Wei’s new machines are designed<br />

to speed the production of both<br />

involute and cycloidal profile pre cision<br />

gears. They are believed to be the<br />

first gear grinding machines on the<br />

market that are capable of handling<br />

both types of gear profile. There are<br />

two versions of the grinding machine,<br />

one for internal gears, the other for<br />

external gears.<br />

Founded in 1981, Chien Wei Precise<br />

Technology Co., Ltd is based in<br />

Fengshan District in southern Kaohsiung,<br />

Taiwan. The company initially<br />

specialised in precision machine tools<br />

such as vertical grinders, jig grinders<br />

and machining centers, together<br />

with co-ordinate measuring machines<br />

(CMMs). Over time, it also diversified<br />

into robotic automation systems.<br />

Chien Wei’s new gear grinding machine is<br />

based entirely on NUM’s latest-generation<br />

Flexium+ 68 CNC platform<br />

Reduction gearboxes<br />

for robotic applications<br />

Most robotic systems demand<br />

smooth, precise and highly<br />

reliable low speed movement.<br />

Deriving that movement from<br />

a motor that runs optimally at,<br />

say, 1000 rpm necessarily<br />

involves some form of speed<br />

reduction gearbox.<br />

Designers typically have a<br />

choice of two types of<br />

reduction gearbox - planetary<br />

drives and cycloid drives.<br />

Robotic systems typically use either<br />

planetary gearboxes equipped with<br />

in vo lute gears, or cycloid drives based<br />

on a combination of a reduced epitrochoid<br />

rotor and a cycloid stator. While<br />

planetary gearboxes have been around<br />

for a long time and enjoy extensive<br />

use, cycloid drives have far fewer moving<br />

parts and offer more effi cient<br />

means of achieving extremely high<br />

re duc tion rates. A speed reducer with<br />

a ratio of 200 : 1 would typically need<br />

a chain of three planetary gear boxes<br />

with twelve moving involute gears.<br />

The same reduction ratio could be<br />

achieved with a cycloid drive, using<br />

one stator and one rotor. However, cycloid<br />

gears are notoriously diffi cult<br />

and expensive to manufacture.<br />

In 2015, Chien Wei decided to bring<br />

gear manufacturing in-house, by devel<br />

oping its own gear grinding machine.<br />

By producing its own gearboxes<br />

the company could control quality,<br />

shorten lead times and reduce costs.<br />

It would also enable it to sell gearboxes<br />

to machine builders - and possibly<br />

the machines themselves to gear<br />

ma nu facturers.<br />

Chien Wei initially based its gear<br />

grinding machine on a Fanuc series<br />

0i-MF CNC system, which it uses for<br />

other machine tools, together with<br />

Mastercam CAD/CAM software and<br />

its own CMM. But it soon became apparent<br />

that the profile complexity of<br />

cycloidal gears meant that CMM data<br />

was inadequate for controlling the<br />

ma nufacturing process. Another major<br />

disadvantage was that customers<br />

wishing to purchase the machines<br />

would also need to invest in an expensive<br />

CAD/CAM system and extra<br />

personnel.<br />

According to Chien Wei’s President,<br />

Mr Lee, “We quickly decided that<br />

what we needed was a CNC system<br />

that fully supported gear grinding<br />

from the outset, so that our customers<br />

could simply input the parameters<br />

of the gear they wanted, with the<br />

CNC then controlling all aspects of<br />

the machine’s dressing and grinding<br />

pro cesses in real-time. NUM was an<br />

obvious choice, because of its proven<br />

expertise in CNC gear grinding applications.<br />

The company was also willing<br />

to collaborate in the joint development<br />

of the CNC system, which<br />

in cludes an application-specific HMI<br />

(human-machine interface) and various<br />

dedicated control functions.”<br />

The new generation of Chien Wei’s<br />

gear grinders together with NUM’s<br />

new profile grinding technology now<br />

provides the ability and flexibility to<br />

manufacture both cycloid and involute<br />

gears on the same machine.<br />

Adrian Kiener, CSO Asia and Managing<br />

Director of NUM Taiwan, points<br />

out that this application highlights<br />

the importance of NUM’s decentralised<br />

support strategy. “By providing<br />

direct access to the CNC experts and<br />

extensive development facilities we<br />

have here in Taiwan, as well as those<br />

in many other countries around the<br />

world, we are able to provide our customers<br />

with a very fast response service<br />

that helps them shorten their<br />

time-to-market significantly. In combination<br />

with the knowledge and experience<br />

of our gear product group in<br />

Switzerland, this led to the complete<br />

60 no. 2, August <strong>2019</strong>

components<br />

Typical planetary gearbox<br />

Typical cycloid gearbox<br />

package that NUM is providing. It<br />

includes the user interface, technology<br />

and calculations, as well as all the<br />

NC cycles.”<br />

Chien Wei’s internal gear grinder is<br />

a 9-axis machine. The work piece table<br />

is mounted on a linear axis that<br />

moves axially towards the grinding<br />

wheel, which is belt-driven (due to<br />

space constraints inside the gear) and<br />

mounted on a vertical axis driven by<br />

a linear motor. As the grinding wheel<br />

spins, it is driven up and down by the<br />

linear axis, while the work piece table<br />

moves in continuously. Both flanks of<br />

the gear are ground simultaneously.<br />

The machine also handles gear dressing.<br />

During the dressing cycle, the entire<br />

tool head is moved horizontally to<br />

the right, and a symmetrical dressing<br />

disk moves along the outer shape of<br />

the grinding wheel in three sections,<br />

right/left flank and tip. Cycloids as<br />

well as involute shapes can be dressed.<br />

The external gear grinder is an<br />

8-axis machine. Broadly similar to the<br />

internal gear grinder in operational<br />

terms, it features a direct drive grinding<br />

wheel. Again, like the internal<br />

gear grinder, it also handles dressing.<br />

However, in this case the shape of the<br />

tooth gap can be reduced epitrochoids<br />

or involutes. Manual correction of the<br />

gear tooth shapes is possible on either<br />

machine.<br />

Both machines are controlled by<br />

NUM Flexium+ 68 CNC systems,<br />

equipped with NUM FS153i touchsensitive<br />

operating panels. The application-specific<br />

HMI that has been<br />

jointly developed by NUM Taiwan<br />

and Chien Wei controls both the<br />

grinding and dressing cycles, and allows<br />

users to fully specify the required<br />

gear profile simply by entering the appropriate<br />

parameters. Graphical DXF<br />

(Drawing Interchange Format) files<br />

can be imported from - and exported<br />

to - CAD systems, and the system fea -<br />

tures a comprehensive database for<br />

grinding wheels and work pieces.<br />

The NC programs are generated<br />

entirely automatically, without any<br />

need for operator involvement.<br />

As Johnny Wu, Sales Manager for<br />

NUM Taiwan, points out, “NUM’s<br />

open architecture CNC platforms,<br />

combined with the company’s willingness<br />

to partner with machine<br />

builders in developing applicationspecific<br />

solutions, is a key differentiator<br />

when it comes to choosing a CNC<br />

supplier.”<br />

Grinding the involute profile of an internal gear on Chien Wei’s new machine<br />

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

no. 2, August <strong>2019</strong><br />


components<br />

Up-to-date tool data from the cloud<br />

TDM Global Line <strong>2019</strong><br />

At the EMO <strong>2019</strong> trade show,<br />

TDM Systems will present its innovative<br />

Tool Data Management<br />

system, TDM Global Line <strong>2019</strong>.<br />

A solution for optimum tool<br />

planning and provision that is<br />

accessible from anywhere in the<br />

world.<br />

TDM Global Line <strong>2019</strong> manages<br />

tools according to items, tool assemblies<br />

and tool lists. The major advantage<br />

of this system is that its central<br />

database is available to users at all<br />

company sites. The central installation<br />

and configuration of the solution<br />

reduces IT costs and promotes synergies<br />

across multiple locations. The new<br />

online tool “TDM WebCatalog” makes<br />

Tool Data Management significantly<br />

easier in many other aspects as well:<br />

At any time, users can quickly access<br />

tool data that is always up to date and<br />

verified, and can integrate this into<br />

their TDM solution with a simple<br />

mouse click.<br />

At the EMO <strong>2019</strong> in Hanover, TDM<br />

Systems GmbH will present its TDM<br />

WebCatalog to the public for the<br />

first time. The cloud application will<br />

be available to customers with TDM<br />

Global Line <strong>2019</strong> and TDM <strong>2019</strong> as<br />

of August. Using the TDM WebCatalog,<br />

users can retrieve the current tool<br />

data of leading manufacturers and retailers<br />

such as ARNO, Hoffman Tools,<br />

Sandvik Coromant and Walter. Other<br />

interesting solutions are currently<br />

being<br />

prepared.<br />

The cloud<br />

catalogs<br />

can be<br />

used to<br />

set up<br />

completely<br />

new tool<br />

databases<br />

within<br />

the company,<br />

as<br />

well as<br />

update<br />

and supplement<br />

existing ones.<br />

The right tool is only a few clicks away, TDM WebCatalog<br />

provides up-to-date and verified tool data from the cloud<br />

TDM Global Line <strong>2019</strong> accelerates machining companies’ manufacturing<br />

processes; the shopfloor work flow can be individually configured<br />

Simple handling<br />

and<br />

time savings<br />

“The highlight of the TDM WebCatalog<br />

is that the data and graphics of<br />

the selected tool can be sent directly<br />

to TDM,” explains Eugen Bollinger,<br />

Head of Sales at TDM Systems. “The<br />

user does not have to create the tool<br />

again separately; rather, it is directly<br />

assigned to the appropriate class and<br />

group structure.” The TDM WebCatalog<br />

also impresses the users with its<br />

flexible text search function. Regardless<br />

of whether the user is searching<br />

according to order number, supplier,<br />

an application or technical parameters,<br />

all the data required for further<br />

processing is available within a very<br />

short time.<br />

Thanks to<br />

the TDM<br />

Web-<br />

Catalog,<br />

the timeconsuming<br />

process<br />

of<br />

creating<br />

a tool database<br />

is<br />

a thing of<br />

the past.<br />

Particularly<br />

during<br />

the introduction of TDM, this had<br />

been a major hurdle for businesses.<br />

“We speed up this process by up<br />

to 80 %,” explains Bollinger enthusiastically.<br />

TDM Global Line <strong>2019</strong>:<br />

efficient tool management<br />

Those who wish to use the TDM<br />

WebCatalog need to register with<br />

TDM Systems and also be users of<br />

TDM Global Line <strong>2019</strong> or TDM <strong>2019</strong><br />

(or later versions). The interaction of<br />

the cloud catalogs with current and<br />

future releases will make the Tool Data<br />

Management of machining compa<br />

nies of all sizes more efficient than<br />

ever before. The central, global ly<br />

ac cessible database, the quick integration<br />

of current and high-quality<br />

tool data and an individually configurable<br />

shopfloor work flow - along with<br />

many other features - considera bly<br />

speed up the entire manu fac turing<br />

process. Additionally, TDM Systems<br />

places great emphasis on the fact that<br />

TDM is not an isolated solution.<br />

Around 20 quality-tested and maintained<br />

CAM interfaces ensure seamless<br />

communication between manufacturing-relevant<br />

systems - an indispensable<br />

aspect in the age of Industrie 4.0.<br />

EMO <strong>2019</strong>, hall 9, booth F24<br />

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

62 no. 2, August <strong>2019</strong>

Dyna Test bar for spindle inspection enables<br />

customers to identify problems in time<br />

components<br />

BIG KAISER, a global leader<br />

in premium high-precision <strong>tooling</strong><br />

systems and solutions for<br />

the metalworking industries,<br />

has announced the Dyna Test, a<br />

precision test bar for inspecting<br />

spindles. Regularly inspecting<br />

with the Dyna Test bar can<br />

identify potential problems with<br />

spindles and bearings, thereby<br />

reducing down time and avoiding<br />

expensive repairs. When machine<br />

spindle damage is not detected<br />

in time, it can have a major<br />

impact on machining operations,<br />

potentially causing product<br />

rejections and excessive tool<br />

wear.<br />

When used, the Dyna Test device<br />

is clamped in the machine spindle<br />

and then rotated. A dial gauge measures<br />

the deflection of the test mandrel,<br />

checking the concentricity of the<br />

spindle. While this test can, of course,<br />

be performed with a tool and identifies<br />

concentricity inaccuracies, it is<br />

still necessary to determine whether<br />

the problem is caused by the spindle,<br />

the shank or the tool itself.<br />

The Dyna Test bar identifies spindle<br />

inaccuracies immediately, elimina ting<br />

all other variables. To meet the re -<br />

quirements of ISO9000, BIG KAISER<br />

can provide a calibration certificate<br />

with traceability on request. To ensure<br />

the highest possible precision,<br />

all Dyna Test bars are produced under<br />

an extremely strict quality control<br />

system.<br />

BIG KAISER offers Dyna Test bars<br />

for BBT, BDV, HSK and BIG CAPTO.<br />

The test bars are protected in a sturdy<br />

aluminum storage case.<br />

Marco Siragna, Head of Product<br />

Management at BIG KAISER, explained,<br />

“By using the Dyna Test, customers<br />

can ensure that undetected<br />

spindle wear is not silently creating<br />

serious future problems.”<br />

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

Larson Electronics releases explosion-proof motor<br />

Larson Electronics, a Texas-based<br />

company with over 40<br />

years of experience spearheading<br />

the industrial lighting and<br />

equipment sectors, announced<br />

the release of an explosion-proof<br />

motor for use in Class I, Division<br />

1 hazardous locations.<br />

This 0.75 HP unit is compatible with<br />

three-phase 460 V AC 50/60 Hz and<br />

features a NEMA 56 motor that can be<br />

installed with industrial systems via<br />

an integrated foot and C-face flange.<br />

The EXP-MTR-3P-230-0.75 HP-1.8 K-<br />

56C explosion-proof motor is rated<br />

for use in Class I, Division 1, Groups C<br />

and D; and Class II, Division 1, Groups<br />

E, F and G hazardous locations. This<br />

fractional explosion-proof motor is<br />

for use in flammable work sites and<br />

is thermally protected, operating on<br />

460 V AC 50/60 Hz. This unit features<br />

a 0.75 HP motor, offering 1.4 full-load<br />

amps at high with 78.6 % full-load<br />

efficiency. This unit can be surface<br />

mounted and comes with a C-face<br />

flange and foot mounting components.<br />

Larson Electronics’ explosion-proof<br />

motor is capable of generating<br />

1,800 RPM and is totally enclosed and<br />

fan cooled. This unit is IP55 rated and<br />

features an ambient temperature rating<br />

of 50 ° C. It is equipped with aluminum<br />

endshields and features Class<br />

F insulation with 1.0 service factor.<br />

This motor comes with 24-inches of<br />

+2/-0 leads for electrical connections<br />

and an unassembled aluminum conduit<br />

box. It is suitable for use in hazardous<br />

locations, industrial facilities,<br />

ma nufacturing and more.<br />

information: www.larsonelectronics.com<br />

no. 2, August <strong>2019</strong><br />


components<br />

Highly accurate linear sensor for<br />

rapid measurement of various surfaces<br />

Color-coded deviation analysis between the point cloud measured by the Chromatic Focus Line sensor and<br />

the CAD model (left) and raster image of a watch plate (right) (© Nomos/Werth)<br />

The Chromatic Focus Line<br />

sensor allows rapid capture of<br />

measured values with over one<br />

million measurement points in<br />

less than three seconds. The measure<br />

ment principle is based on<br />

chromatic aberration, making it<br />

largely independent of the surface<br />

condition of the workpiece.<br />

Werth Messtechnik presents the latest<br />

innovation in its extensive selection<br />

of sensors: with the Chromatic<br />

Focus Line (CFL) sensor, entire workpiece<br />

geometries are captured rapidly.<br />

Using different lenses, the measurement<br />

uncertainty and range can be<br />

adapted to a particular application.<br />

Due to the large axial measurement<br />

range, exact tracking of the workpiece<br />

geometry is unnecessary, so large areas<br />

can be rapidly and easily captured by<br />

scanning. Workpieces with large varia<br />

tions in height may be scanned along<br />

a pre-defined 3D path. The Chromatic<br />

Focus Line sensor measures workpieces<br />

with diffuse, reflective, and transparent<br />

surfaces, as well as surfaces with<br />

large inclination.<br />

The CFL projects a series of about<br />

200 white light points onto the surface<br />

of the workpiece. The light reflected<br />

from the surface is spectrally<br />

analyzed to determine the distance<br />

between the sensor and the surface.<br />

This new linear sensor is the first to<br />

be able to perform a complete 3D capture<br />

of the workpiece with both high<br />

accuracy and high speed. It measures<br />

about one million measurement<br />

points in three seconds.<br />

The Chromatic Focus Line sensor has<br />

another interesting function: in ad di -<br />

tion to the wavelength of the re flec ted<br />

light, its intensity is also analyzed and<br />

a raster image of the workpiece surface<br />

is generated. Subsequent analysis with<br />

image processing soft- ware allows mea -<br />

sure ment “in the image” of geometric<br />

features or definition of the workpiece<br />

coordinate system. The positions for<br />

measurements with a variety of other<br />

sensors are determined on this basis,<br />

without requiring a sensor change.<br />

With the unparalleled accuracy<br />

of the CFL at high measuring speed,<br />

precision components and micro-features<br />

are measured. The sensor can be<br />

used on highly reflective or transparent<br />

workpieces, such as die stamps and<br />

carbide or diamond tools, but also on<br />

diffuse reflective plastic components.<br />

The high point density allows the determination<br />

of topography for a wide<br />

variety of surfaces to be captured, such<br />

as precision mechanical workpieces<br />

like watch chassis plates. With in-process<br />

measurement of LED array coplanarity,<br />

semiconductor technology is<br />

another typical area of application<br />

for the CFL. The measurement result<br />

is the entire shape of the workpiece<br />

surface in the form of a point cloud,<br />

which can be used to determine flatness<br />

or roughness and to measure geometric<br />

elements. A nominal-to-actual<br />

comparison with color-coded deviation<br />

plots is also possible.<br />

further information: www.werth.de<br />

64 no. 2, August <strong>2019</strong>

components<br />

Filtermist International unveils two upgrades<br />

at EMO <strong>2019</strong><br />

UK based oil mist collectors<br />

manufacturer Filtermist<br />

International Limited, which is<br />

celebrating its 50th anniversary<br />

this year, will be introducing its<br />

latest product developments at<br />

EMO <strong>2019</strong>.<br />

Filtermist will be launching an improved<br />

version of its F Monitor - a<br />

mo nitoring system that advises machine<br />

operators when the extraction<br />

unit needs servicing, as well as warning<br />

them of any potential blockages<br />

which may reduce the effectiveness of<br />

the system.<br />

technology has also had to adapt. The<br />

introduction of high-pressure coolant,<br />

often using neat oil, can result in<br />

a high-density mist containing large<br />

volumes of submicron particulate<br />

which either blocks or passes through<br />

many traditional oil mist filters.<br />

Designed specifically for the larger<br />

FX models, FX Fusion combines a<br />

hi-tech synthetic self-draining media<br />

filter with Filtermist’s proven centrifugal<br />

technology - offering a cost-effective<br />

alternative to other products in<br />

the high-pressure coolant market.<br />

EMO <strong>2019</strong>, hall 7, booth A62<br />

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

Filtermist’s F Monitor 2 features Bluetooth<br />

connectivity which allows it to<br />

link to a dedicated app on a smart<br />

phone or tablet which allows the<br />

user to adjust the time, air flow, temperature<br />

and vibration levels to suit<br />

particu lar applications.<br />

Also available is the F Monitor 2+<br />

which, like the F Monitor 2, measures<br />

airflow and time, with additional<br />

functionality to measure vibration and<br />

motor temperature via a sensor that attaches<br />

directly to the Filtermist motor.<br />

Both models use a globally recognised<br />

traffic light system of colored<br />

warning lights to alert machine opera<br />

tors when an oil mist collector needs<br />

servicing, or if any of the filters are<br />

blocked.<br />

FX Fusion<br />

Filtermist will also be showing the<br />

new size Fusion filter which has been<br />

designed especially to fit onto Filtermist’s<br />

FX4002 and FX5002 models,<br />

crea ting FX Fusion. With the same<br />

func tionality as the S Fusion neat oil<br />

mist collector, FX Fusion is designed<br />

to help customers solve their neat oil,<br />

high-pressure extraction requirements.<br />

Modern machining processes have<br />

seen machine tool manufacturers increase<br />

speeds and feeds to improve efficiencies,<br />

meaning the surrounding

impressum<br />

ISSN 2628-5444<br />

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company finder<br />

3D Systems.................................................. 28<br />

Agathon..................................................31, 38<br />

ANCA.............................................................16<br />

BIG KAISER................................................ 63<br />

BOEHLERIT GmbH & Co. KG................10<br />

CERATIZIT Group...............................14, 45<br />

Curtis Machine Tools Ltd. /<br />

Element Six...........................................27, 38<br />

EMAG........................................................... 55<br />

EMVA............................................................ 30<br />

Felsomat GmbH & Co. KG...................... 58<br />

FILTERMIST............................................... 65<br />

Fraunhofer Institute for<br />

Manufacturing Engineering and<br />

Automation................................................ 46<br />

FRITZ STUDER AG................................... 49<br />

GEFERTEC...................................................51<br />

GF Machining Solutions......................... 28<br />

GFMS............................................................ 54<br />

Hermle......................................................... 54<br />

Hyperion Materials & Technologies... 35<br />

ITA TOOLS Company.............................. 28<br />

Jic-tools (JIMMORE)................................ 25<br />

joke Technology........................................ 30<br />

editorial<br />

advertising index<br />

JUARISTI..................................................... 56<br />

Kern Microtechnik....................................52<br />

LACH DIAMANT.................................12, 18<br />

Larson Electronics................................... 63<br />

LASERFAIR Shenzhen..............................27<br />

Leitz.............................................................. 22<br />

LEUCO..........................................................32<br />

MAPAL..............................................14, 33, 36<br />

METALEX.................................................... 26<br />

MMC hardmetal................................. 24, 34<br />

NUM............................................................. 60<br />

Oerlikon Balzers......................................... 8<br />

Paul Horn GmbH...................................... 23<br />

PLATIT AG.................................................. 42<br />

REISHAUER AG........................................... 6<br />

TDM Systems............................................. 62<br />

Tecno.team.............................................. 50<br />

TOYODA...................................................... 56<br />

TSUBAKI KABELSCHLEPP.................... 34<br />

TYROLIT............................................... 26, 38<br />

Walter Maschinenbau GmbH................57<br />

Werth Messtechnik.................................. 64<br />

ZECHA................................................... 12, 32<br />

AFAG Messen und Ausstellungen GmbH.......................................................................37<br />

Boehlerit GmbH & Co. KG........................................................................................17<br />

CeramTec GmbH.............................................................................................................29<br />

CERATIZIT Deutschland GmbH......................................................................................5<br />

DURATEC Hartstoffe GmbH..........................................................................................27<br />

Effgen..............................................................................................................................65<br />

FRITZ STUDER AG..........................................................................................................21<br />

Jimmore International Corp........................................................................................51<br />

Krebs & Riedel Schleifscheibenfabrik GmbH & Co. KG..............................................3<br />

Lach Diamant..................................................................................outside back cover<br />

Landesmesse Stuttgart.........................................................................................41<br />

Oemeta Chemische Werke GmbH...............................................................................15<br />

Oerlikon Surface Solutions AG.......................................................................................13<br />

PLATIT AG............................................................................................. inside front cover<br />

Reishauer AG.......................................................................................................... cover<br />

RUF Maschinenbau GmbH & Co.....................................................................................9<br />

SUMITOMO Electric group....................................................................................25<br />

TYROLIT Schleifmittelwerke................................................................................33<br />

VDW Verein Deutscher Werkzeugmaschinenfabriken e.V........................35<br />

66 no. 2, August <strong>2019</strong>

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