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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.

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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 />

ta:C


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 />

KREBS & RIEDEL<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 />

KREBS & RIEDEL<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 />

hv07di19


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 />

THE REVOLUTION<br />

IN TURNING<br />

TEAM CUTTING TOOLS<br />

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

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

Tooling the Future<br />

www.ceratizit.com


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 />

7


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 />

phase, BALINIT HARD CARBON<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 />

BALINIT® HARD CARBON<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 />

Mainz/Germany


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 />

11


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 />

A LACH DIAMANT<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 />

WITHOUT<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 />

EFFICIENCY WITHOUT BIOCIDES<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 />

www.oemeta.com


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 />

www.boehlerit.com


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 />

19


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 />

SEPTEMBER<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 />

23


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 />

BINDERLESS PCD GRADE<br />

FOR BRITTLE MATERIALS<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 />

25


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 />

METALEX<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 />

THE ADVANCED SUPPLIER FOR<br />

SUPERHARD MATERIALS<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 />

27


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 />

MACHINING<br />

SOLUTION<br />

FOR<br />

CAST IRON ∙ AEROSPACE<br />

HARDENED STEEL<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 />

29


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 />

31


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 />

ZECHA PRECISION TOOLS LIMITED<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 PRECISION TOOLS LIMITED ensures that<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 />

www.tyrolit.com


news & facts<br />

companies<br />

TSUBAKI focuses on continuity<br />

On July 1, Henning Preis (49) took over as president<br />

& CEO of TSUBAKI KABELSCHLEPP GmbH and<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 and<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 />

35


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 />

39


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 />

41


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 />

43


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 />

45


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 />

47


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 />

49


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 />

JIMMORE<br />

International Corp.<br />

TEL: +886-(0)4-22605352<br />

FAX: +886-(0)4-22608765<br />

E-mail: trade@jimmore.com.tw<br />

https://nine9.jic-tools.com.tw


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 />

53


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 />

HIGH-PERFORMANCE-LINE series<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 />

55


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 />

TRONIC POWER DIAMOND 400<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 />

TRONIC POWER and HELITRONIC<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 />

POWER DIAMOND 400<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 />

use the HELITRONIC TOOL STUDIO<br />

grinding and eroding software.<br />

information: www.walter-machines.com<br />

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

57


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 />

dihw DIAMANT<br />

HOCHLEISTUNGSWERKZEUGE<br />

<strong>hp</strong> <strong>tooling</strong><br />

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

WiN woodworking<br />

INTERNATIONAL<br />

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 />

61


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 />

63


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


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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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