hp tooling 2022 #1

Intelligent generating grinding – quality assurance for e-transmission gears ■ Plasma etching optimization on complex geometries ■ Future of tool grinding ■ More efficiency in the manufacture of cardiovascular products

Intelligent generating grinding – quality assurance for e-transmission gears ■ Plasma etching optimization on complex geometries ■ Future of tool grinding ■ More efficiency in the manufacture of cardiovascular products


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ISSN 2628-5444<br />

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

Machine Tools, PCD, PVD, CVD, CBN, Hard Metal <strong>2022</strong> – 1<br />

»Contour-profiled«<br />

Step into the future...<br />

...deep grinding<br />

fast<br />

precise<br />

cost-effective<br />

®<br />

since 1922<br />

celebrates its 100 th anniversary<br />

www.lach-diamant.de<br />

Titelbild <strong>hp</strong> <strong>tooling</strong>_contour_01/22.indd 1 31.01.22 12:31<br />

■ Intelligent generating grinding – quality assurance for e-transmission gears ■ Plasma etching optimization on<br />

complex geometries ■ Future of tool grinding ■ More efficiency in the manufacture of cardiovascular products ■

editorial<br />

Spring fever...<br />

Eric Schäfer<br />

editor-in-chief<br />

...is something else, but it’s not<br />

just us trade journalists who are<br />

feeling excited these days. This<br />

is probably the case for everyone<br />

in the industry who will finally<br />

be able to visit trade shows again<br />

this spring. The trade fair duo<br />

TIMTOS and TMTS in Taiwan<br />

has already started at the end<br />

of February – despite travel<br />

restrictions. In Germany GrindTec, the leading international<br />

trade fair for grinding technology, is on the agenda in March.<br />

And finally again personal meetings, even if still under<br />

pandemic-conditioned precautionary measures.<br />

much higher demands on manufacturing precision despite<br />

their simpler design. Precision is also the keyword in tool<br />

grinding. At GrindTec machine manufacturer Haas will be<br />

showing what the future of tool grinding could look like.<br />

Not only precision, but also efficiency plays a decisive<br />

role in manufacturing processes in the medical technology<br />

industry. How the most precise laser control and positioning<br />

systems contribute to efficient production in the manufacture<br />

of cardiovascular products is another highlight you can read<br />

about in this issue. All this can only be a small foretaste of<br />

future events. Because one thing is certain: we can expect a<br />

hot trade show summer.<br />

This issue of <strong>hp</strong> <strong>tooling</strong> is also about grinding applications.<br />

We take a detailed look at generating grinding in the pro duction<br />

of gearboxes for electric cars. These, by the way, place<br />

www.harnisch.com/<strong>hp</strong>-<strong>tooling</strong>/en/<br />

…have you already been here this year?<br />

Eric Schäfer<br />

editor-in-chief<br />

Milling competence<br />

right down the line<br />

■ 45° Milling - Smooth cut and high metal<br />

removal at extremely smooth running<br />

■ 90° Milling - Highest productivity, cost<br />

reduction and optimal distribution of cutting<br />

force<br />

■ HFC-Milling - High metal removal under the<br />

most difficult conditions<br />

■ 3-D Milling - Universal applicable tool<br />

system for mould and die<br />

■ Solid carbide milling - Over 1000 products<br />

for every application<br />


table of contents<br />

cover story<br />

LACH DIAMANT looks back on 100 years – 11 th part<br />

«Contour-profiled» shows its claws 6<br />

materials & tools<br />

Automatic profile changing system awarded 10<br />

Machining carbide with PCD solid head milling cutters 11<br />

Hard, harder, SteelCon 12<br />

Slot milling of narrow grooves 13<br />

Plasma etching optimization on complex geometries<br />

made possible by PLATIT’s 3D etch indicator<br />

R. Zemlicka, Y. Li, P. Tapp, H. Bolvardi, A. Lümkemann 14<br />

Range of carbide rods and purpose-built solutions extended 17<br />

Stable process and improved surface finish thanks to vibration-damped boring bars 18<br />

processes<br />

Production systems and manufacturing technologies<br />

for chassis and powertrain of rail vehicles<br />

Manfred Berger, MAG IAS and Leo Schreiber, BOEHRINGER 26<br />

Intelligent generating grinding –<br />

quality assurance for e-transmission gears already on board 30<br />

Flexibility, transparency and cost savings 34<br />

CNC chamfering 35<br />

machining center<br />

Tornos: a source of strength to medical device manufacturers around the world 36<br />

Future of tool grinding “Dear tool grinders, don’t say later that you didn’t know” 38<br />

The latest grinding machine development with an innovative machine concept 40<br />

Top productivity for large workpieces 41<br />

components<br />

More efficiency in the manufacture of cardiovascular products 42<br />

We don’t have to be there to be there 44<br />

Live tool speed increaser realizes 9X tool cost savings in less than a year 45<br />

New CNC software simplifies usage of latest five-axis machine tools 46<br />

Clear conditions for tool grinding 49<br />

news & facts 19<br />

fairs 21, 50<br />

impressum & company finder 51<br />

4 no. 1, March <strong>2022</strong>

Steel machining<br />

made easy<br />

The new ISO-P grades with indicator layer<br />

for high-performance turning processes!<br />

CVD multilayer coating<br />

➝ latest Dragonskin coating<br />

technology!<br />

- improved wear resistance<br />

- versatile steel machining<br />

Find out more at:<br />

cutting.tools/gb/en/iso-p-grades<br />


CERATIZIT is a high-tech engineering<br />

group specialising in cutting tools and<br />

hard material solutions.<br />

Tooling the Future<br />


cover story<br />

LACH DIAMANT looks back on 100 years – 11 th part<br />

Poly – poly – or what?<br />

«Contour-profiled» shows its claws. A renaissance for<br />

the metal-bond diamond and CBN grinding wheel.<br />

Horst Lach, managing director and CEO of<br />

LACH DIAMANT, agreed to write an ongoing series<br />

of articles about the development of diamond and<br />

CBN tools and grinding wheels in modern industries.<br />

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

we are excited to have this pioneer of technol ogy share<br />

some insights from his 61 years of professional experience<br />

in the diamond tool business. This time only a few<br />

historical remarks – but indeed most relevant regarding<br />

the trade shows in <strong>2022</strong>.<br />

The attentive reader may wonder whether the author has<br />

chosen the wrong title for this series “Poly – poly – or what?”,<br />

since he is writing about diamond and CBN grinding wheels.<br />

Wikipedia provides the (comforting) answer: “Poly, from<br />

the Greek, a word stem found in many German loanwords,<br />

meaning “much, or many”… The author is relieved and<br />

points out how many individual CBN and diamond grains<br />

are present in the grinding layer, depending on the desired<br />

concentration – a truly polycrystalline structure.<br />

By comparison, the “aggregates”, commonly known as<br />

polycrystalline inserts since 1973, are “baked” during hig<strong>hp</strong>ressure<br />

synthesis and studded with many, many microscopic<br />

CBN and diamond grains; “baked” so compactly and<br />

sturdily that they changed the world of machining, practically<br />

providing a single cutting edge.<br />

Back to the grinding wheels: “Bite”, yes – but “claws”?<br />

This requires a brief look back into the history of metalbond<br />

grinding wheels, and in doing so I found the following<br />

excerpts from the book “Diamanten im Dienste der Industrie“<br />

(a translation from the English original “Industrial Applications<br />

of the Diamond” by Norman R. Smith) fascinating:<br />

“The use of diamonds for grinding hard materials has been<br />

known for hundreds of years. Already in 1824 Pritchard used<br />

diamondiferous wheels for manufacturing diamond microscope<br />

lenses. These wheels were actually produced by<br />

hammering diamond particles into the iron body. By the<br />

middle of the century, these one-layer diamond wheels were<br />

already commonly used. It is known that differently sized<br />

natural diamand grains were hammered into copper coins<br />

for the production of small diamond wheels. It is very likely<br />

that such hammered diamond wheels were used to grind the<br />

first carbides (HM).<br />

Many patents followed, based on a wide variety of different<br />

procedures to produce these kind of grinding wheels. Most<br />

procedures utilized cold pressing and sintering or infiltration<br />

methods still used today. It is also worth mentioning that,<br />

Example of a popular application of metal bond<br />

diamond grinding wheels in the 60’s and 70’s<br />

in 1927, Krupp in Germany developed “Widia”, a cemented<br />

carbide, initially meant for drawing dies for wire drawing,<br />

which presented new challenges to the –up to now – small<br />

market for diamond wheels. The resin-bondgrinding wheel<br />

with today’s quality was still far from being invented. In<br />

addition to the natural diamond grains, a rubber-bond wheel<br />

was available for polishing tasks until the mid fifties.”<br />

A breakthrough for grinding with diamonds<br />

Until the early 1970’s, metal-bond diamond wheels were<br />

still used on simple tool sharpening machines (Simon L 15),<br />

e.g. for grinding chip grooves on hardened carbide turning<br />

tools, mainly because of their form stability and hardness;<br />

or as pointed profile wheels on optical profile sharpening<br />

machines (example PTW).<br />

Until today the glass industry is an exception which, without<br />

diamonds, could not have gifted us with gems such<br />

as crystalline glasses. One would hear similar stories from<br />

ceramics manufacturers. The year 1955 brought a breakthrough<br />

for grinding with diamonds, the development of<br />

diamond grain synthethis, which first became available two<br />

years later to diamond tool manufacturers.<br />

6 no. 1, March <strong>2022</strong>

cover story<br />

Schematic picture of a metal bond diamond profiling<br />

grinding wheel, «contour-profiled», during deep grinding<br />

of a threading insert – cost efficient: one instead of three<br />

«Contour-profiled»<br />

shows its claws – the diamond grain,<br />

exposed by the EDG procedure, available up to<br />

90 % maximal removal or chip formation<br />

Ten years later, the innovative ability to metal-coat diamond<br />

grains completed this breakthrough. Thanks to the<br />

metal coating, the diamond grain could be securely fastened<br />

to the grinding wheel’s resin – with the result that the abrasive<br />

grain could be used up to 80/85 % until it broke out of its<br />

bonding.<br />

Suddenly it was possible to use diamond grinding wheels<br />

even for rough grinding; until then only silicon-carbide<br />

grinding wheels were recommended for rough grinding.<br />

Polyamide grinding wheels were the highlight for this<br />

development for deep grinding of carbide and hardened<br />

steel, developed by the manufacturers Winter & Son and<br />

LACH DIAMANT, e. g. Gresso® (Winter) and tressex® (LACH<br />

DIAMANT). These innovations also contributed to the<br />

boom-like development of the carbide tool industry.<br />

Resin versus metal-bonds<br />

Grinding wheels with metal-bonds could not hold up to this<br />

development – apart from their edge stability and profile<br />

retention, they were inferior to the high-performance grinding<br />

wheels based on phenole and polyamide resins as well as<br />

with hybrid and ceramic bonds. The CBN or diamond grains,<br />

closely embedded into the metal-bond, simply did not allow<br />

for enough chip space for fast, erosive grinding.<br />

To manufacture complex components, modern CNC-controlled<br />

tool sharpening machines allow for a fully automated<br />

exchange of different grinding wheels, but the disadvantage<br />

of the bonds used, compared to the metal-bonds, remains.<br />

Patent “Procedure and device for machining metal bond<br />

materials” (EP0076997) with priority of 1981-10-05<br />

Increasing cost pressure in mass production, and grinding<br />

more and more frequently requested profile components<br />

– concave and convex structures with maximal<br />

profile precision of up to 2-4 µ – led to a “déjà-vu” at LACH<br />

DIAMANT and the renaissance of metal-bond diamond and<br />

CBN grinding wheels.<br />

One plus one equals two. Firstly, the discovery of spark/<br />

electrical discharge grinding in 1978, and secondly the European<br />

patent:<br />

“Procedure and Device for Machining Metal-bond Materials”<br />

(EP0076997) with priority of 1981-10-05.<br />

The additional expertise relative to the electric discharge<br />

grinding (EDG) procedure, developed by LACH DIAMANT –<br />

superior to the EDM wire procedure – combined all of the advantages;<br />

thanks to the form electrode broadly set to the metalbond<br />

grinding wheel during profiling, all of the following is<br />

possible: concave or convex profiles; high precision, even for<br />

inner profiles with 2 - 4 µ; even a zero-radius is possible. Since<br />

even grain sizes of 180 µ can be processed, a large chip space<br />

(with grain protrusion of up to 90 %) is available to users during<br />

the grinding process.<br />

Deep grinding revolutionized<br />

It can rightly be argued that the «contour-profiled» procedure,<br />

developed by LACH DIAMANT, revolutionized deep<br />

grinding. The «contour-profiled» profiling grinding wheels<br />

and the sharpening machine «mini-contour», especially developed<br />

for the EDG-Plus dressing procedure, were first introduced<br />

at EMO 2017 in Hanover.<br />

no. 1, March <strong>2022</strong><br />


cover story<br />

Product manager Alexander Kern chose a few especially interesting<br />

cases from the abundance of actual customer experiences,<br />

and the results speak for themselves:<br />

Deep grinding of solid carbide threaded inserts from the<br />

solid with «contour-profiled» grinding wheels<br />

Another manufacturer’s resin-bond diamond grinding wheels<br />

were compared with a metal-bond «contour-profiled» profile<br />

grinding wheel. For this application three resin-bond wheel<br />

sets with the dimensions of 150-3-5, form 1A1, 150-4-5-45°,<br />

form 1V1, and model design 150-3-5-R1, form 1F1, were<br />

clamped consecutively onto the grinding mandrel.<br />

By comparison, the «contour-profiled» profile diamond<br />

grinding wheel had a width of 15 mm and a diameter of<br />

150 mm. The wheel geometry was manufactured according to<br />

the contour of the threading insert so that only one wheel was<br />

needed to produce the insert.<br />

The solid carbide (K30) inserts were produced via deep<br />

grinding on a tool sharpening machine, using emulsion of<br />

3-5 %, and with a nominal capacity of 20 kw.<br />

‣ A: operating parameters of the resin-bond wheels<br />

After 100 inserts the wheels had to be taken off the<br />

machine, due to loss of profile, and had to be profiled<br />

on an external dressing machine. With an usable grinding<br />

layer height of 5 mm, and assuming 33 dressings, this<br />

would result in a tool life of 3,300 finished inserts.<br />

The total projected cost for solid carbide inserts would<br />

be 9.73 EUR per insert. This cost calculation considers<br />

cost for abrasives at 0.075 EUR per insert, as well as<br />

machine costs and additional setup times due to the<br />

necessary dressing procedures.<br />

‣ B: operating parameters of the «contour-profiled»<br />

metal-bond profile diamond grinding wheel<br />

Compared to the resin-bond wheels (A), the «contourprofiled»<br />

metal-bond wheels had to be taken off the<br />

machine only after 2,300 finished inserts in order to<br />

guarantee a profile precision of 0.005 mm. With an usable<br />

grinding layer height of 0.005 mm and assuming 50<br />

dressings, this would result in a total tool life of 115,000<br />

finished inserts for the «contour-profiled» wheel (B).<br />

Comparison of operating parameters of resin bond wheels to<br />

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

EDM wire procedure versus<br />

EDG spark erosion procedure<br />

Over the last three years, the successes of «contour-profiled»<br />

became known within the industry for revolutionary cost<br />

and time savings in deep grinding carbides, ceramics, hardened<br />

and even soft steel. Market insiders did not fail to notice<br />

that even suppliers of EDM wire machines addressed this<br />

issue. I almost gained the impression that customers as well<br />

as competitors were led to believe that the possibilities of the<br />

profiling procedure developed by LACH DIAMANT were<br />

simply the same, 1:1 so to speak. This strikes me as strange.<br />

New EDM wire machines are advertised with statements<br />

such as “0.05 mm precision, porous structures on surface<br />

topology of the grinding layer as well as highest repeatable<br />

precision, erosion wires of 0.1 mm are capable to profile<br />

A<br />

resin-bond wheels<br />

B<br />

«contour-profiled»<br />

metalbond profile<br />

diamond grinding wheel<br />

cost of wheel 3 x 245 = 735 € 1,093 €<br />

v s 24 m/s 20 m/s<br />

a e ges 3 mm 3 mm<br />

v f 15 mm/min 25 mm/min<br />

t s 3.35 min 2.40 min<br />

dressing cycle after 100 inserts 2,300 inserts<br />

dressing amount 0.15 mm 0.1 mm<br />

dressing time,<br />

including setup time<br />

approx. 15 min<br />

approx. 30 min<br />

The total projected cost for solid carbide inserts would be<br />

6.8095 EUR per insert. This cost calculation considers<br />

cost for abrasives at 0.000095 EUR per insert, as well as<br />

machine costs. Considering the high tool lives, setup<br />

costs were negligible.<br />

The EDG-plus sharpening machine profiles with top precision,<br />

even for grain sizes of up to 170 μ, without having to stumble<br />

over up to 90 % exposed diamond or CBN bodies, compared to<br />

EDM wire procedure; it is not without reason that here at<br />

LACH DIAMANT we refer to the «claws» of our so-called<br />

«contour-profiled» grinding wheel, whether with concave or<br />

convex profile which provide maximal removal amounts due<br />

to the cleared chip space<br />

8 no. 1, March <strong>2022</strong>

cover story<br />

Example of a multi-part<br />

«contour-profiled» metal<br />

bond CBN grinding<br />

wheel, Ø 400 x 110 mm,<br />

on an «EDG-plus-minicontour-profiled»<br />

EDG<br />

sharpening machine –<br />

during service, profiles<br />

can be resharpened with<br />

highest precision and<br />

repeatable quality for<br />

high tool times<br />

this new technology – from the change of resin-bond or<br />

hybrid grinding wheels to the metal-bond «contour-profiled»<br />

grinding wheel.<br />

More than bite<br />

First of all we should focus on tool life; this is an area in<br />

which metal-bonds have always been superior to any other<br />

bond variations. However the structural design typical for<br />

this type of manufacturing, does not provide a lot of room<br />

for the embedded diamond or CBN grain for long-lasting<br />

chip formation. What does the “hot EDM wire” do when it is<br />

almost – as one should visualize it – “stumbling” over the single<br />

abrasive grains and as it is continuing its path in a wavelike<br />

fashion? One thing should be clear: the EDM “hot wire”<br />

is not able to cut the protruding diamond or CBN grains.<br />

The EDG procedure is different. Here the electrode moves<br />

towards the grinding layer as in deep grinding; the wheel will<br />

be profiled with highest precision, concave or convex. Profile<br />

widths of 200 mm and more as well as the production of<br />

«contour-profiled» grinding wheels with, at present, up to<br />

600 mm diameter are possible.<br />

In doing so, the «contour-profiled» wheel shows – depending<br />

on the size of the diamond or CBN grain – not only its<br />

“bite” but also its “claws”, even at a grain size of 180 µ.<br />

With the latter, the «contour-profiled» grinding wheel profits<br />

from a trailblazing bond technology which exposes each<br />

grain up to 90 % and holds it in place, even during aggressive<br />

deep grinding tasks; «contour-profiled» becomes a “milling<br />

wheel” with until now undreamt-of potential for grinding<br />

carbides, hardened steel, ceramics and even soft steel.<br />

«Contour-profiled» CBN grinding wheel with test<br />

template for a hair trimmer – with a profile depth<br />

of 13.5 mm and a width of 0. 5 mm;<br />

operation during deep grinding<br />

We are indeed experiencing a renaissance of the metalbond<br />

diamond and CBN grinding wheel.<br />

Horst Lach<br />

grinding layers in metallic bond matrix with diamond or<br />

CBN grain sizes of up to 46/50 µ, with a wheel diameter of<br />

max. 150 mm.”<br />

However, we can check these attributes off as doable – but<br />

we are not including into our efficiency calculation the enormous<br />

amount of wire needed for contouring the processed<br />

profile. Let’s ask ourselves what customers may expect from<br />

Have a look at our «contour-profiled»<br />

CBN grinding wheels video!<br />

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

no. 1, March <strong>2022</strong><br />


materials & tools<br />

Automatic profile changing system awarded<br />

At the end of the previous year, Leitz GmbH & Co.<br />

KG was awarded the Innovation Award of the Eastern<br />

Württemberg Chamber of Industry and Commerce –<br />

for the development of the flexTrim3 automatic profile<br />

changing system.<br />

The patented flexTrim3 system was developed specifically<br />

for quick profile changes within continuous production processes<br />

and successfully brought to market. Since its market<br />

launch about two years ago, furniture manufacturers all<br />

over the world have been producing their furniture<br />

components such as carcasses or fronts with this<br />

tool system. FlexTrim3 shows its full effect in batch<br />

size 1 production and leads to significant increases<br />

in the efficiency of the production process by<br />

elimina ting downtimes for profile changes. Since<br />

manual tool changes take a lot of time, this way of<br />

changing profiles is simply uneconomical for batch<br />

size 1 production. Alternative systems for tool<br />

changing are usually very expensive and also require<br />

a lot of installation space within the machine.<br />

The flexTrim3 profile changing system from Leitz;<br />

the name already describes what is probably the greatest<br />

advantage of the system: the combination of three different<br />

profiles in one tool makes edge processing more flexible<br />

than ever before<br />

The product of the world market leader from Oberkochen<br />

convinced and inspired the jury in particular with regard to<br />

the evaluation criteria “economic efficiency”, “originality”,<br />

“chance of realisation and use”, “effort for the idea” and “sustainability”.<br />

The “Award for Patents and Talents” is handed<br />

out every year to regional companies, persons and organisations<br />

for the development and implementation of outstanding<br />

innovative ideas.<br />

With flexTrim3, Leitz offers an economically acceptable<br />

solution for this type of challenge. The<br />

3-in-1 concept allows automatic profile change between<br />

three different profiles. In terms of profile<br />

types, all customer-specific radius and chamfer<br />

profiles, up to a depth of 3 mm, can be implemented<br />

on the profile rims. Even the combination<br />

of “with feed and against feed” is individually possible<br />

with the system. The profile changes are programme-controlled<br />

and take just 30 seconds! The<br />

result is a maximally efficient batch size 1 production<br />

with less manpower and very short downtimes.<br />

The flexTrim3 system is also universally applicable<br />

in the materials to be machined. Softwood, hardwood,<br />

veneer or plastic laminates can be processed<br />

reliably and in top quality. On the machine side, the<br />

new flexTrim3 system can be used specifically on<br />

HOMAG FF32 units.<br />

In terms of sustainability, particular emphasis<br />

was placed on using resources as efficiently as possible.<br />

By using diamond cutting edges, the tools<br />

have very long lifetimes of one year and more before<br />

they need to be replaced. In this way, the pressure<br />

switching mechanism can be reused at the end<br />

of the tool’s lifetime.<br />

flexTrim3 provides more flexibility and efficiency in edge processing<br />

as well as an increase in productivity. A solution from<br />

Leitz showing how practice-oriented and value-added tool<br />

development works today. It proves its innovative strength<br />

and clearly underpins its position as world market leader.<br />

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

10 no. 1, March <strong>2022</strong>

materials & tools<br />

Machining carbide with PCD solid<br />

head milling cutters<br />

KNOW THE<br />

FEELING?<br />

With new PCD solid head milling cutters, MAPAL is extending<br />

the possibility of machining carbide and other hard-brittle materials<br />

to smaller diameters.<br />

Deep-drawing dies in the die and mould sector are often made of durable<br />

carbide. Machining them by die-sinking or grinding is tedious. Machining<br />

with coated solid carbide tools often suffers from high wear and low tool<br />

life. PCD tools are a cost-efficient alternative here.<br />

Then stop using complicated<br />

controllers for precision motion.<br />

You shouldn’t need a Ph.D. in<br />

control systems to program your<br />

controller.<br />

The new PCD solid-head milling cutters convince customers<br />

with short process times and long tool lives when machining carbide<br />

and other hard-brittle materials<br />

With Automation1, you can now<br />

reduce your set up time—in<br />

many cases, from days down to<br />

minutes—thanks to a user-friendly,<br />

intuitive interface and machine<br />

setup wizard. Automation1 is the<br />

most user-friendly precision motion<br />

control platform available.<br />

The punches and moulds usually require tools with diameters less than<br />

6 mm. To execute these tool dimensions in PCD, full-head PCD must be<br />

used, since smaller milling cutters have no room for brazed-on cutting edges<br />

and their substructure. With new geometry, number of cutting edges and<br />

arrangement, MAPAL now makes it possible to machine hard-brittle workpiece<br />

materials with diameters from two to six mm.<br />

To produce the perfect PCD tool according to customer requirements,<br />

blanks are kept in stock in the appropriate sizes. PCD is more expensive<br />

than solid carbide, but thanks to the longer tool life and shorter process<br />

times, break-even is quickly reached. In tests, the new milling cutters<br />

managed significantly higher feeds per tooth compared to solid carbide and<br />

therefore a much higher machining volume.<br />

In addition to carbide, hard-brittle materials also include zirconia, a ceramic<br />

material used in dental technology. The new PCD solid head milling<br />

cutters from MAPAL are also an alternative to solid carbide in this area.<br />

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

Motion made easy.<br />

Visit uk.aerotech.com/automation1

materials & tools<br />

Hard, harder, SteelCon ®<br />

More performance in the machining of hardened steel for injection molds<br />

In tool and mold making, the machining of hardened<br />

steels beyond 50 HRC is standard. It nevertheless<br />

remains a discipline for specialists, especially for manu -<br />

facturers of precision tools. The milling cutters used<br />

are subject to very heavy wear. Tool manufacturers<br />

therefore know that long and, above all, process-reliable<br />

tool life is only possible with a coating adapted<br />

to the tool. With the new HiPIMS coating material<br />

SteelCon®, CemeCon now offers the best solution for<br />

this.<br />

Hard machining, especially the machining of injection molds<br />

made of hardened steels with more than 50 HRC, is a demanding<br />

application: the materials are both hard and tough,<br />

and alloying components that increase corrosion resistance<br />

further complicate the machining tasks. “Here the milling<br />

cutters used literally cut their teeth due to enormous feed<br />

rates and high temperatures at cutting speeds of up to 250 m/<br />

min. At the same time, the highest surface qualities are<br />

required even for the smallest contours. In order to machine<br />

as economically as possible under these extreme conditions,<br />

first-class precision tools are required. A prerequisite for this<br />

is the right coating. With our new HiPIMS coating material<br />

SteelCon® we provide the right basis for this,” says Manfred<br />

Weigand, product manager Round Tools at CemeCon.<br />

Perfect combination for top performance<br />

SteelCon® is the second silicon-doped HiPIMS coating<br />

material from CemeCon. While InoxaCon® is excellently<br />

suited for machining stainless steel, titanium and difficultto-machine<br />

materials, the coating experts have developed<br />

SteelCon® specifically for machining hardened steels beyond<br />

50 HRC. Whether dry or wet, milling, drilling, reaming or<br />

threading – SteelCon® is the ideal solution in hard machining<br />

thanks to its outstanding properties.<br />

“The HiPIMS coating material SteelCon® is very wear-resistant,<br />

on the one hand due to its high hardness, and on the<br />

other hand due to its toughness coupled with excellent adhesion.<br />

It has a dense layer structure and the thermal stability<br />

has been increased. Top conditions for best performance!”<br />

emphasizes Manfred Weigand. “Another plus: the wear behavior<br />

of SteelCon® differs significantly from other coatings<br />

available on the market. Tool manufacturers as well as users<br />

are enthusiastic and give us consistently positive feedback:<br />

‘We have never seen such homogeneous wear behavior.’ This<br />

ensures high process stability.”<br />

Since no droplets can form thanks to the HiPIMS process,<br />

SteelCon® is extremely smooth. This means that nothing<br />

stands in the way of optimum chip and heat removal. The<br />

tool can dissipate the heat in the chips, and process stability<br />

increases. Excellent surface qualities are achieved, so that the<br />

user can often save subsequent work – in some cases even the<br />

polishing of their workpieces.<br />

Those who use tools with a matched SteelCon® coating<br />

when machining hardened steels are on the safe side: shorter<br />

machining times, reduced setup and handling procedures,<br />

and better surface quality significantly reduce the bottom<br />

line costs. “We achieve such advantages thanks to the extreme<br />

hardness, high toughness, smooth surface, maximum<br />

adhesion, high thermal stability and dense morphology of<br />

SteelCon®,” says Manfred Weigand in summary.<br />

Tools with a<br />

coordinated<br />

SteelCon® coating<br />

ensure shorter<br />

machining times,<br />

reduced setup<br />

and handling<br />

processes, and<br />

better surface<br />

quality. The<br />

bottom line<br />

is that this<br />

significantly<br />

reduces costs<br />

Whether wet or dry – SteelCon® significantly increases tool life<br />

when milling injection molds made of hardened steels<br />

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

12 no. 1, March <strong>2022</strong>

materials & tools<br />

Slot milling of narrow grooves<br />

Paul Horn GmbH has extended<br />

its circular interpolation system for<br />

slot milling of grooves. Horn offers<br />

the tools in cutting widths from<br />

0.25 mm (0.01") to 1 mm (0.039"),<br />

depending on the diameter.<br />

Depending also on tool diameter, the<br />

maximum milling depth (tmax) is between<br />

1.3 mm (0.051") and 14 mm<br />

(0.551"). Inserts are available with different<br />

coatings to suit the material<br />

being machined. Thanks to its mass,<br />

the solid carbide tool shank ensures<br />

vibration damping throughout the mill<br />

ing process. All variants of tool shank<br />

have an internal coolant supply.<br />

Circluar milling in general<br />

The circular milling system offers users<br />

a host of process advantages: it is fast,<br />

reliable and achieves good surface finish.<br />

During the process, the tool plunges<br />

into the material either at an angle<br />

or horizontally and may then be driven<br />

on a helical path. This means that threads, for example, can be manufactured to a<br />

high level of reproducible quality. When compared to machining using indexable<br />

inserts on larger diameters or solid carbide milling cutters on smaller diameters,<br />

circular interpolation milling is generally more economical. Circular interpolation<br />

milling cutters have a wide range of applications: they are able to machine steel,<br />

special steels, titanium and special alloys. These precision tools are especially well<br />

suited to groove milling, circular interpolation milling, thread milling, T-slot milling<br />

and profile milling.<br />

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

visit us at:<br />

hall 5, stand 5012<br />

Fast, reliable and good surface finish –<br />

the circular milling system from Horn

materials & tools<br />

Plasma etching optimization on complex geometries<br />

made possible by PLATIT’s 3D etch indicator<br />

written by R. Zemlicka, Y. Li, P. Tapp, H. Bolvardi, A. Lümkemann<br />

Wear-resistant hard coatings and cutting-edge<br />

preparation took over key roles<br />

in the optimizations of precision tools. In<br />

addition to the correct selection of the micro<br />

tool geometry, the hard coating must<br />

also be adapted to suit the application [1] .<br />

The best protective hard coating system<br />

could not show its full potential without<br />

fulfilling the basic requirement: sufficient<br />

adhesion to the substrate material. Prior<br />

to the thin film deposition, the substrate<br />

material must be free from any impurities<br />

on the atomic scale. This can be achieved<br />

in high-vacuum PVD systems with glow<br />

discharge techniques igniting a plasma<br />

directly on the substrates and carousel at<br />

several hundred volts prior to the PVD<br />

and/or PECVD process [2 ,3, 4] .<br />

Several inventions were proposed to suppress<br />

the inhomogeneous material removal rate typical<br />

for glow discharge methods [5, 6, 7] . However,<br />

current methods for estimating the etching rate<br />

are insufficient to evaluation the resulting homogeneity, with<br />

limited applica bil ity only on planar substrates [6] . So far, it has<br />

not been possible to reliably evaluate the etching rate for most<br />

critical substrate surfaces such as a cutting edge of the cutting<br />

tools.<br />

The pinion cutter covered with homogenous interference color layer prior to<br />

the etching process and the resulting change of the color after the etching; the<br />

changed colors provide the 3D map of the etching efficiency<br />

figure 2<br />

With this article we would like to introduce our patented<br />

3D plasma etch indicator, which is considered as a breakthrough<br />

in plasma etching profile measurement. This new<br />

approach provides a 3D visual profile of the plasma etching<br />

efficiency over several tens of centimeters of the surface of<br />

any shape with the ability to tailor a dedicated etch profile to<br />

industrial parts of interest.<br />

figure 1<br />

Scale of interference colors of a thin TiO 2 layer with<br />

its corresponding thickness, see literature [8]<br />

To obtain such a 3D etch profile, the studied samples (e.g.,<br />

cutting tools) were covered with thin films reflecting homogenously<br />

a single interference color (e.g., blue). These samples<br />

were then placed into the coating chamber and the plasma<br />

etching procedure was carried out for a defined time. After<br />

plasma etching, the thin inference layer on the sample surface<br />

decreased unevenly in terms of thickness. Since thin film<br />

interference color corresponds directly to its thickness, the<br />

resulting color at any point of the surface provides the information<br />

on the etching efficiency at that particular point with<br />

a resolution of 5 to 10 nanometer.<br />

Figure 1 shows a scale of interference colors of a thin TiO 2<br />

layer with its corresponding thickness reprinted from the literature<br />

[8] . Figure 2 illustrates the usage of the 3D etch indicator<br />

on the pinion cutter. With help of the scale in figure 1, the<br />

color change after etching reveals the reduction of the layer’s<br />

thickness and thus the etching efficiency on the 3D profile of<br />

the substrate.<br />

When using the 3D plasma etch indicator, we found important<br />

information regarding the character of glow discharge<br />

processes, which are finally being used to optimize the coating<br />

adhesion:<br />

1.<br />

It was discovered that the measurement of the etch rate<br />

on the flat test pieces is not relevant for the estimation of<br />

the etch efficiency on industrial samples with 3D geometries.<br />

14 no. 1, March <strong>2022</strong>

materials & tools<br />

A) B)<br />

figure 3<br />

joint loading of one drill and two samples of different shapes<br />

A) left, two samples of different shapes coated with homogenous<br />

interference layer; right, samples of the same shape<br />

(and originally the same coating) after the etching process<br />

B) drill before and after the etching process<br />

figure 4<br />

Three tools coated with a homogenous light blue<br />

TiO 2 56 ± 5 nm thick layer and subsequently etched for 10 min;<br />

each tool was etched separately in an argon discharge of<br />

three different parameters<br />

Figure 3 shows on the left the joint loading of one drill,<br />

one triangle shaped test piece and one round shaped test<br />

piece. All three samples were coated with homogenous light<br />

blue layer and underwent together the same plasma etching<br />

procedure.<br />

Figure 3A) on the left shows the homogenous 56 ± 5 nm<br />

thick light blue color layer (see the scale in figure 1) on two<br />

different test samples. The right side of the figures shows the<br />

samples after the etching process. While the dark blue color<br />

in the center of the samples corresponds to the thickness of<br />

38 ± 5 nm, the edges of the samples which were exposed to the<br />

plasma were etched completely.<br />

Figure 3B) shows the condition of the drill before and after<br />

the etching procedure. This tool was etched inhomogeneously.<br />

In addition to the clear material removal gradient from top to<br />

bottom, we can also notice the residual blue color on the cutting<br />

edge, which shows that this crucial part of the tool was<br />

not etched sufficiently.<br />

By comparing the etch profile on the samples and on the<br />

drill surface, we can conclude that flat test pieces are not able<br />

to provide relevant information on the etch efficiency of complex<br />

3D samples. Therefore, the mechanical measurement of<br />

the etch profile of partially covered flat samples cannot be<br />

sufficient and must be replaced by, e.g., our 3D plasma etch<br />

indicator.<br />

2.<br />

We found a way to measure and visualize that different<br />

discharge parameters result in very different distributions<br />

of plasma etching.<br />

While methods using the flat test pieces were able to compare<br />

the etching efficiency of different discharge parameters<br />

on one dimensional scale, we found out that the actual 3D<br />

character of the etch profile differs signifi cantly for different<br />

discharge parameters. Figure 4 shows an example of the<br />

three tools coated with a homogenous light blue 56 ± 5 nm<br />

thick layer and subsequently etched for 10 min. Each tool was<br />

etched separately under different Ar plasma etching conditions,<br />

which we refer to as B), C) and D). Figure 4A) shows<br />

one tool prior the 10 min etching.<br />

The effect of etching with parameters B) is shown in figure<br />

4B). We can see that the interference layer was completely<br />

removed on the cutting edges, however, more than 60 % of<br />

the interference layer remains in the flute and on the drill<br />

land. Such a discharge can sufficiently etch sharp edges, but it<br />

is very ineffective on a flat surface.<br />

Figure 4C) shows more effective etching on the land, but<br />

about 50 % of the interference layer remains in the flute.<br />

The etching with parameters D) shown in figure 4D) shows<br />

a very different etching profile.<br />

Unlike the previous examples, we see the inhomogeneity of<br />

etching from top to bottom. In addition, we see a very different<br />

etch profile when looking at the flute and the cutting<br />

edge. While the flute is etched efficiently, we notice a blue residue<br />

on the cutting edge (see the red circles). This shows that<br />

while we can success fully clean the flute at these parameters,<br />

the most important part – the cutting edge – remains almost<br />

undertreated.<br />

3.<br />

Loading dependency of the material removal rate<br />

by plasma etching.<br />

Our 3D etch indicator showed a significant depen dency of<br />

the etching efficiency on the loading of the tools. While the<br />

etch indicator on Ø 6 mm drills placed in a standard shank<br />

tool hol der showed a relatively high etching efficiency with in<br />

standard etching pro ces ses, micro tools placed in a micro tool<br />

holder showed barely any effect within the identical etching<br />

process. This might be seen as counter-intuitive because we<br />

might expect that micro tools required milder plasma etching<br />

than the Ø 6 mm shank tools.<br />

no. 1, March <strong>2022</strong><br />


materials & tools<br />

figure 5<br />

Ø 0.5 mm end mill<br />

source Louis Bélet<br />

This information has significantly helped the development<br />

of a coating process, in particular, for micro tools. A TiSibased<br />

coating was deposited on cemented carbide Ø 0.5 mm<br />

end mill as seen in the figure 5 and tested within wet machining<br />

of titanium alloy at a cutting speed 50 m/min. The<br />

micro tool cutting tests were carried out at Louis Bélet. The<br />

burr heights were measured at regular distances depending<br />

on the machining length.<br />

The graph in the figure 6 shows the result of a dedicated<br />

etching optimization, indicating a much lower burr height for<br />

the micro tool coating with optimized etching compared to<br />

the standard plasma etching generally used for Ø 6 mm shank<br />

tools. While conventional optimization of plasma etching<br />

required feedback from cutting tests for each set of parameters,<br />

with the 3D etch indicator, feedback was visible to the<br />

naked eye immediately after the plasma etch test.<br />

figure 6<br />

Development of burr height as a function of milling length<br />

source Louis Bélet<br />

As a result, the presented 3D plasma etch indicator provides<br />

a tool for selecting the right combination of etch parameters<br />

and provides dedicated etching processes adapted to<br />

the ge ome tries to be coated. This could have never been verified<br />

and adjusted across the PVD industry, even though the<br />

community is aware that the etching process for shank tools<br />

should be different than a gear cutting tool or a segmented<br />

die. In this way, 3D etch profiling can be used to ensure that<br />

the selected etching strategy leads to 100 % treatment of the<br />

sample surface with complex 3D geometry.<br />

Acknowledgement<br />

We would like to thank Louis Bélet for providing us with the<br />

results of the cutting tests.<br />

Literature<br />

[1]<br />

Luemkemann A., et al. (2012)<br />

Schneidkantenpräparation und Beschichtung<br />

XIII. Internationales Oberflächenkolloquium, Chemnitz<br />

[2]<br />

Mattox D. M. (2010)<br />

Handbook of physical vapor deposition (PVD) processing<br />

William Andrew, chapter 13.11.2 – Sputter Cleaning<br />

[3]<br />

Vossen J. L. (1979)<br />

“The preparation of substrates for film deposition<br />

using glow discharge techniques”<br />

Journal of Physics E: Scientific Instruments 12.3: 159<br />

[4]<br />

Chapman B. N. (1980)<br />

Glow discharge processes: sputtering and plasma etching,<br />

Wiley, chapter 7 Plasma etching<br />

[5]<br />

Foller M., et al.<br />

(Aug. 4, 1992)<br />

“Process for<br />

plasma-chemical cleaning<br />

prior to pvd or pecvd<br />

coating”<br />

U.S. patent no. 5,135,775<br />

[6]<br />

Vetter J., et al. (1993)<br />

“Arc-enhanced glow<br />

discharge in vacuum arc<br />

machines”<br />

Surface and coatings<br />

technology, 59.1-3:<br />

152-155<br />

[7]<br />

Cselle, T., et al. (2017)<br />

“Glow Discharge<br />

Apparatus and Method<br />

with Lateral Rotating Arc<br />

Cathodes”<br />

EP2705522 (B1)<br />

[8]<br />

Antończak, A. J., et al.<br />

(2014)<br />

The influence of process<br />

parameters on the<br />

laser-induced coloring<br />

of titanium<br />

Applied Physics A, 115(3),<br />

1003-1013<br />

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

16 no. 1, March <strong>2022</strong>

materials & tools<br />

Range of carbide rods and<br />

purpose-built solutions<br />

extended<br />

Brings solutions<br />

to the surface.<br />

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

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

premium manufacturer whose outstanding expertise<br />

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

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

carbide tools that are suitable for a wide range of<br />

applications.<br />

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

many years’ experience with regard to carbide blanks and<br />

semi-finished products for the precision tool industry<br />

and offers a multitude of special material grades with varying<br />

grain sizes. Alongside the well-established micro-grain<br />

carbide grades HB10F, HB20F and HB30F, Boehlerit also<br />

offers two grades in the ultrafine-grain range with the<br />

HB20UF and the HB44UF. HB20UF is ideal for the processing<br />

of composites as well as for HSC milling from 60<br />

HRC. HB44UF is used for all rotating tools within the field<br />

of HSC technology and for the machining of hardened<br />

steels up to 62 HRC. HB40T, a special carbide grade that<br />

was developed by Boehlerit, offers a combination of toughness<br />

and wear resistance that is ideal for the roughing of<br />

titanium.<br />

When it comes to milling titanium, its toughness poses<br />

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

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

this, tools require a sophisticated combination of metallic<br />

hard materials that have contradictory properties. Carbide<br />

grade HB40T is the ideal combination of high wear resistance<br />

and toughness. Boehlerit offers the HB40T grade<br />

as a bar material. These blanks are perfect for the manufacturing<br />

of shaft tools of the kind that are used for titanium<br />

roughing applications. The HB40T is thus the starting<br />

point of choice for <strong>tooling</strong> applications in almost all<br />

indus trial areas where titanium is processed. Typical areas<br />

of application include the processing of aeroplane structure<br />

parts or engine components, products in the medical technology<br />

sector or components for chemical or energy plants.<br />

Boehlerit is also an ideal partner for customised solutions<br />

for pre-formed blanks for milling and drilling tools.<br />

The Boehlerit portfolio also includes the extremely wearresistant<br />

ultrafine-grain HB05UF and the XS10 grade, optimised<br />

for diamond coating. HB05UF constitutes an ideal<br />

solution for the machining of abrasive compound matesrials<br />

as well as for materials within a hardness range of<br />

> 62 HRC. For detailed information and recommendations<br />

see www.boehlerit.com or refer to our catalogue “Carbides<br />

and Semi-Finished Products”.<br />

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up new horizons for the full spectrum of highly innovative<br />

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trade fair at the heart of the market, GrindingHub<br />

presents the complete range: machines, tools and the<br />

entire production environment.<br />

GrindingHub – the new hub of grinding technology.<br />

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

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materials & tools<br />

Stable process and improved surface finish<br />

thanks to vibration-damped boring bars<br />

Quality and efficiency in the machining process are<br />

measured using an extremely wide range of parameters.<br />

Naturally, surface quality and process security are<br />

among them. The new vibration-damped boring bars<br />

by Team Cutting Tools from the CERATIZIT Group<br />

ensure that these criteria are met.<br />

These boring bars reliably reduce vibrations and, together<br />

with the flexibility of the brand-new exchangeable head<br />

system, guarantee top quality at a low price.<br />

Uncontrolled vibrations have resulted in the demise of<br />

many an expensive workpiece and reduced efficiency for the<br />

machine operator. But long tool overhangs are often essential<br />

during turning, counterboring or threading so what is the<br />

answer? “Depending on the material to be machined, these<br />

conditions inevitably lead to vibrations that are eventually<br />

transferred to the workpiece, with catastrophic effects on the<br />

surface quality,” explains Christoph Retter, product manager<br />

at Team Cutting Tools from the CERATIZIT Group. “And,<br />

these are not the only limitations for an efficient machining<br />

process – accelerated wear through to tool breakage is also<br />

a factor. At CERATIZIT we are counteracting this with a<br />

new addition to our range, the combination of vibration-damped<br />

boring bars and a flexible exchangeable head<br />

system."<br />

Quiet, drill!<br />

Up until now, machine operators have usually reduced vibrations<br />

by decreasing process parameters such as cutting depth,<br />

cutting speed or feed. “With regards to the highest possible<br />

efficiency, this is only a temporary workaround as the cycle<br />

time often decides whether an order is profitable or not.<br />

The CERATIZIT solution is a newly developed exchangeable<br />

head system, which can be used with base holders, but also<br />

with special boring bars. These effectively minimise irksome<br />

vibrations thanks to the damping system in the tool body,”<br />

explains Christoph Retter.<br />

The result is, that instead of having to reduce the cutting<br />

values, even higher parameters are possible. Machining processes<br />

with long tool overhangs can be completed far more<br />

quickly with vibration-damped boring bars than with those<br />

that are not damped. The damped tools improve the surface<br />

quality in particular and extend tool lives, whilst at the same<br />

time the tool and the machine spindle are under consider -<br />

ably less strain. “This provides for greater sustainability,<br />

as all of the components used last significantly longer. Together<br />

with the cost savings achieved from extended tool life,<br />

the machine operator can now complete even tricky tasks<br />

with an increased sense of calm,” says Christoph Retter.<br />

Thanks to vibration damping, applications are possible<br />

that would not be under normal conditions with minimum<br />

cutting parameters.<br />

The basis for optimised machining with the vibrationdamped<br />

boring bars is the newly developed modular<br />

exchangeable head system from CERATIZIT; with<br />

a selection of eight different exchangeable heads,<br />

it is extremely variable, flexible and versatile<br />

Variable system for a wealth of options<br />

The basis for optimised machining with the vibrationdamped<br />

boring bars is the newly developed modular exchangeable<br />

head system from CERATIZIT. With a selection<br />

of eight different exchangeable heads, it is extremely variable,<br />

flexible and versatile, which will save on purchase and<br />

warehousing costs. Due to the clever positioning of the coolant<br />

nozzle, the exchangeable head system also benefits from<br />

highly efficient cooling and improved chip clearance.<br />

Standard versions of the base holders are available from<br />

CERATIZIT in 200, 218 and 283 mm lengths and diameters<br />

of 25, 32 and 40 mm. “The vibration-damped versions come<br />

in 150, 185 and 225 mm lengths,” says Christoph Retter. Their<br />

strengths include process security, reduced costs per component,<br />

optimum chip clearance and improved surfaces –<br />

and the full benefits can be seen irrespective of the materials<br />

to be machined.<br />

Boring bars: quality not available off the shelf<br />

“These components are without a doubt a highlight from<br />

the brand-new exchangeable head system product range for<br />

turning. The vibration-damped boring bars bring a sense<br />

of peace and calm during machining for both the tool and<br />

user, and the best part is that the costs are manageable and<br />

machine operators won’t need to reach for a stress ball!”<br />

summarises Christoph Retter with a wink.<br />

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

18 no. 1, March <strong>2022</strong>

Change of management<br />

at Krebs & Riedel<br />

news & facts<br />

For reasons of age, Mr. Jost Riedel (65) retired from the management<br />

of Krebs & Riedel Schleifscheibenfabrik and handed over his function<br />

on February 1 st , <strong>2022</strong>, to his brother, Dipl.-Vw. Florian Riedel (53).<br />

Dr. Ingo Kuhl, Jost Riedel, Dipl.-Vw. Florian Riedel<br />

(from left to right).<br />

Jost Riedel worked for Krebs & Riedel for a total of 38 years. Of these, he was a<br />

partner for 36 years and presided over the company as managing director for<br />

24 years. Krebs & Riedel is now headed by Dipl.-Vw. Florian Riedel and Dr.<br />

Ingo Kuhl. Mr. Jost Riedel will remain with the company as a shareholder and<br />

consultant.<br />

Jost Riedel has successfully led the company through numerous crises. Under<br />

his leadership, sales and the size of the company doubled. Future challenges<br />

are mainly the expansion of the site in Bad Karlshafen and the extension of the<br />

national and international sales structures. By arranging the succession in the<br />

management from among the shareholders, the continuity for a successful cooperation<br />

with customers and business partners is ensured. The shareholders and<br />

the employees of Krebs & Riedel thank Jost Riedel for his many years of successful<br />

management and wish him all the best for his retirement.<br />

further information: www.krebs-riedel.de

news & facts<br />

Robot density nearly doubled globally<br />

International Federation of Robotics reports<br />

The use of industrial robots in factories around the<br />

world is accelerating at a high rate: 126 robots per<br />

10,000 employees is the new average of global robot<br />

density in the manufacturing industries – nearly double<br />

the number five years ago (2015: 66 units). This is<br />

according to the 2021 World Robot Report.<br />

By regions, the average robot density in Asia/Australia is 134<br />

units, in Europe 123 units and in the Americas 111 units.<br />

The top 5 most automated countries in the world are: South<br />

Korea, Singapore, Japan, Germany, and Sweden.<br />

e.g. in the cost-efficient production of solar panels and in the<br />

continued transition towards electric vehicles. Several car<br />

manufacturers have announced investments to further equip<br />

their factories for new electric drive car models or to increase<br />

capacity for battery production. These major projects will<br />

create demand for industrial robots in the next few years.<br />

Europe<br />

Europe’s most automated country is Germany – ranking 4 th<br />

worldwide with 371 units. The annual supply had a share of<br />

33 % of total robot sales in Europe 2020 – 38 % of Europe’s<br />

“Robot density is the barometer to track the<br />

degree of automation adoption in the manufacturing<br />

industry around the world,” says<br />

Milton Guerry, president of the International<br />

Federation of Robotics.<br />

Asia<br />

The development of robot density in China is<br />

the most dynamic worldwide: due to the significant<br />

growth of robot installations, the density<br />

rate rose from 49 units in 2015 to 246 units<br />

in 2020. Today, China’s robot density ranks 9 th<br />

globally compared to 25 th just five years ago.<br />

Asia is also the home of the country with the world’s<br />

highest robot density in the manufacturing industry: the Republic<br />

of Korea has held this position since 2010. The country’s<br />

robot density exceeds the global average seven-fold (932<br />

units per 10,000 workers). Robot density had been increasing<br />

by 10 % on average each year since 2015. With its globally<br />

recognized electronics industry and a distinct automotive<br />

industry, the Korean economy is based on the two largest<br />

areas for industrial robots. Singapore takes second place with<br />

a rate of 605 robots per 10,000 employees in 2020. Singapore’s<br />

robot density had been growing by 27 % on average each year<br />

since 2015.<br />

Japan ranked third in the world: in 2020, 390 robots were<br />

installed per 10,000 employees in the manufacturing industry.<br />

Japan is the world’s predominant industrial robot<br />

manufacturer: the production capacity of Japanese suppliers<br />

reached 174,000 units in 2020. Today, Japan’s manufacturers<br />

deliver 45 % of the global robot supply.<br />

North America<br />

Robot density in the United States rose from 176 units in<br />

2015 to 255 units in 2020. The country ranks seventh in the<br />

world – ahead of Chinese Taipei (248 units) and China (246<br />

units). The modernization of domestic production facilities<br />

has boosted robot sales in the United States. The use of<br />

industrial robots also aids to achieve decarbonization targets<br />

operational stock is in Germany. The German robotics industry<br />

is recovering, mainly driven by strong overseas business<br />

rather than by the domestic or European market. Robot demand<br />

in Germany is expected to grow slowly, mainly supported<br />

by demand for low-cost robots in the general industries<br />

and outside traditional manufacturing.<br />

France has a robot density of 194 units (ranking 16 th in the<br />

world), which is well above the global average of 126 robots<br />

and relatively similar compared to other EU countries like<br />

Spain (203 units), Austria (205 units) or The Netherlands (209<br />

units). EU members like Sweden (289 units), Denmark (246<br />

units) or Italy (224 units), have a significantly higher degree<br />

of automation in the manufacturing segment.<br />

As the only G7 country – the UK has a robot density below<br />

the world average of 126 units with 101 units, ranking<br />

24 th . Five years ago, the UK’s robot density was 71 units. The<br />

exodus of foreign labor after Brexit increased the demand for<br />

robots in 2020. This situation is expected to prevail in near<br />

future, the modernization of the UK manufacturing industry<br />

will also be boosted by massive tax incentives, the “superdeduction”:<br />

From April 2021 until March 2023, companies<br />

can claim 130 % of capital allowances as a tax relief for plant<br />

and machinery investments.<br />

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

20 no. 1, March <strong>2022</strong>

fairs<br />

news & facts<br />

GrindTec <strong>2022</strong><br />

Groundbreaking innovations and new theme worlds<br />

If not now, then when: after four years the leading<br />

specialist trade fair for grinding technology<br />

is finally getting underway again. From March 15<br />

to 18 more than 300 exhibitors will use GrindTec<br />

<strong>2022</strong> to present their innovations to the world<br />

market.<br />

In any case, anticipation for the long-missed live fair<br />

is great – because one thing has been learned and can<br />

also be seen in the active participant numbers: no matter<br />

how professionally digital formats are made, they<br />

can never replace the personal encounter between<br />

two people. But, and we are also aware of this, trade<br />

shows are increasingly being supplemented (and better)<br />

by digital offerings and can thus also help to open up<br />

new markets.<br />

Grinding Match –<br />

the digital way to GrindTec <strong>2022</strong><br />

With its “Grinding Match” platform, GrindTec offers<br />

grinding technology experts worldwide, who otherwise<br />

wouldn’t have any access, the opportunity of visiting<br />

GrindTec <strong>2022</strong>. Via this platform there is also the<br />

possibility of actually getting in touch with participating<br />

companies. This should please all exhibitors missing<br />

customers from certain countries. For this purpose<br />

they will be provided with codes by the organizer, helping<br />

their customers to grant access to the trade show.<br />

GrindTec <strong>2022</strong> –<br />

technical and technological highlights<br />

The focus at GrindTec <strong>2022</strong> is clearly on details. It will<br />

map all clusters of grinding and tool grinding technology<br />

in a targeted, precise and comprehensive manner,<br />

without forgetting the upstream and downstream peripheral<br />

areas.<br />

Visitors can also look forward to innovations in the field<br />

of coating technology, trend-setting technologies for cutting<br />

edge preparation or innovative laser processing or tool soldering<br />

systems.<br />

As before, “smart” technologies form the big bracket of<br />

GrindTec. They link the most important processes in grinding<br />

and tool grinding technology with each other. Monitoring<br />

and controlling production technology via smartphone or tablet<br />

is no longer a dream of the future, but it is only possible with<br />

a modern network economy. The manufacturers of machines<br />

and peripheral systems, of process and tool technology have<br />

developed answers to this, which they will present on site.<br />

This can be experienced live at the special show “GrindTec<br />

Factory”: the entire process chain of a tool grinding operation<br />

including the necessary technical interfaces will be installed<br />

close to reality.<br />


kapp-niles.com<br />

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

Against the background of newly developed grinding<br />

machines, measuring devices, automation solutions, innovations<br />

for the preparation of cooling lubricants as<br />

well as high-precision clamping devices and techniques,<br />

GrindTec offers unlimited potential for unprecedented<br />

impulses and ideas.<br />

Being an important aspect, because the call for fresh<br />

business models and processes is becoming louder in<br />

the industry. Here support can come from a wide range<br />

of innovations from the software sector, which make<br />

the upcoming transformation processes possible in the<br />

first place. At GrindTec, the latest versions of various<br />

user software solutions will be presented, which are indispensable<br />

for the operation and programming of machines,<br />

measuring devices and systems.

news & facts<br />

An excellent 2021 for the italian industry of machine tools,<br />

robotics and automation; also in <strong>2022</strong> a strong growth<br />

The year 2021 was extremely positive for the Italian<br />

industry of machine tools, robotics and automation,<br />

which reported double-digit increases for all key<br />

economic indicators. This trend should continue in<br />

<strong>2022</strong>, the year when all ground lost in 2020 should be<br />

recovered.<br />

This is in short what was illustrated by Barbara Colombo,<br />

president of UCIMU-SISTEMI PER PRODURRE, the Italian<br />

machine tools, robots and automation systems manufacturers’<br />

association, during the traditional end-of-year press<br />

conference.<br />

As highlighted by the preliminary year’s data processed by<br />

the Studies Dept. & Business Culture of UCIMU-SISTEMI<br />

PER PRODURRE, in 2021 production reached € 6,325 million,<br />

marking a 22.1 % upturn compared with the previous<br />

year.<br />

This is due to the excellent trend of Italian manufacturers’<br />

deliveries to the domestic markets, increased by 27.8 %<br />

to € 2,965 million, as well as to the positive performance of<br />

exports, achieving € 3,360 million, i.e. 17.4 % more than<br />

in the previous year.<br />

Based on the ISTAT data processing by UCIMU, in the<br />

period January-September 2021 (latest available data), Italian<br />

exports of machine tools started to grow again in almost all<br />

countries of destination. Sales to Germany, which turned out<br />

to be the first country for the “Made in Italy” exports of the<br />

sector, went up to € 256 million (+ 38.4 %). The other major<br />

destination countries were the United States, € 251 million<br />

(+ 9.7 %), China, € 154 million (- 5.3 %), Poland, € 118 million<br />

(+29 %) and France, € 117 million (+1.2 %).<br />

The domestic market was extremely lively, as shown by<br />

the data of consumption, which increased by 30.4 % in 2021<br />

compared to 2020, attaining a value of € 4,645 million. The<br />

export/production ratio went down by 2 % points, standing at<br />

53.1 %. In line with the upswing reported by these indicators<br />

was also the growth of turnover, exceeding the value of € 9<br />

billion in 2021, after collapsing to € 7.5 billion in 2020.<br />

Despite the dynamic demand and the improvement in the<br />

context, in 2021 the Italian industry of the sector was not able<br />

to achieve a full recovery after the downturn experienced in<br />

2020 because of the difficulty in sourcing components and<br />

raw materials. This phenomenon caused a delay between the<br />

collection of orders and the actual delivery of machinery.<br />

In particular, according to the survey conducted last<br />

October by the UCIMU Economic Studies Department &<br />

Business Culture on a representative sample of enterprises in<br />

the sector, 95 % of the companies said that there are late supplies.<br />

The average delay is 3 months, which, added to the usual<br />

one and a half months of normal waiting time, makes the<br />

delivery time of supplied components and materials increase<br />

to 4 ¼ months. According to the interviewed enterprises, the<br />

impact of this delay on the delivery time of machinery is estimated<br />

at 4 months. As a result, the average delivery time of<br />

machinery is currently 9 months versus the 5 months, which<br />

manufacturers habitually used to guarantee their customers.<br />

The positive trend reported in 2021 should continue even in<br />

<strong>2022</strong>, the year when there should be a full recovery from the<br />

collapse due to the outbreak of the pandemic.<br />

further information: www.ucimu.it<br />

Gleason launches LINE in Japan<br />

Gleason Corporation is pleased to announce the release<br />

of its new LINE account, designed to enhance<br />

communications with customers in Japan.<br />

Effective immediately, Gleason now offers customers in<br />

Japan a better way to access news and and communicate<br />

directly with Gleason. The new Line account enhances access<br />

to news on the latest Gleason gear technology developments,<br />

innovative products and services, as well as offering an additional,<br />

direct communications channel for customers’ information<br />

needs. Gleason’s Line account will also give information<br />

on upcoming events, trainings and webinars, and connect<br />

to the popular Gear Trainer Webinar series.<br />

Gleason’s Line account complements the wide array of<br />

Social Media channels and electronic information channels<br />

already provided by Gleason Corporation.<br />

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

22 no. 1, March <strong>2022</strong>

news & facts<br />

Nomination for outstanding user and<br />

customer experience<br />

A revolutionary product innovation from the UNITED<br />

GRINDING Group, C.O.R.E. – Customer Oriented<br />

REvolution has been nominated for a UX Design Award<br />

for its outstanding user and customer experience. The<br />

panel selected it from a pool of 300 submissions from<br />

58 countries.<br />

C.O.R.E. from the UNITED<br />

GRINDING Group brings to<br />

life a new machine interaction<br />

concept based on a modern<br />

hardware and software<br />

architecture. It standardizes<br />

op eration of all machine<br />

tools from the UNITED<br />

GRINDING Group, with a<br />

new 24-inch multi-touch<br />

C.O.R.E. panel offering intuitive<br />

controls similar to a<br />

smartphone and personalized<br />

customization options. The<br />

clean design of the C.O.R.E.<br />

panel features only a few buttons,<br />

ensuring clean visuals.<br />

The virtual function keys<br />

are also only displayed when<br />

needed, further reducing complexity and eliminating potential<br />

sources of error. The role-specific interface, with the option<br />

of limiting the display to relevant information for the<br />

user role, also promotes simplification. In this way, C.O.R.E.<br />

improves the working experience both for the machine’s<br />

operators as well as set-up and maintenance personnel.<br />

Another new feature is the integrated front camera, which<br />

enables quick and easy support also via video calls di rectly<br />

from the panel.<br />

The merits of C.O.R.E. also impressed the jury of the UX<br />

Design Awards <strong>2022</strong>, earning it a nomination from among<br />

300 products and projects from 58 nations for its convincing<br />

user and customer experience. The award is renowned as the<br />

top global competition for outstanding experiences, presented<br />

by the International Design Center Berlin (IDZ).<br />

Just the beginning<br />

However, C.O.R.E. encompasses much more than revo lu tionary<br />

machine operation. The groundbreaking hardware and<br />

software architecture opens up new possi bil ities for networking,<br />

controlling and monitoring the pro duction process, and<br />

thus for process optimization. It also lays the foundations for<br />

the operation of modern IoT applications and thus opens the<br />

door to the digital future.<br />

further information: www.grinding.ch<br />

no. 1, March <strong>2022</strong><br />


news & facts<br />

companies/fairs<br />

EMAG sells EMAG eldec GmbH<br />

as part of a management buy-out (MBO)<br />

EMAG eldec GmbH becomes eldec Induction GmbH. All jobs will be retained.<br />

The previous managing director Thomas Rank takes over the shares of eldec GmbH from the EMAG Group.<br />

Global machine builder EMAG signed a purchase agreement<br />

with eldec induction GmbH under which the EMAG Group<br />

will sell all of its shares in EMAG eldec GmbH. Eldec produces<br />

and sells highly efficient induction heating technology<br />

for a wide range of industrial applications. In addition to<br />

generators for induction heating, the company offers toolmaking<br />

(inductors) and machine tools for induction hardening.<br />

At the EMAG Group, eldec products have been used<br />

in the design of production lines and the construction of<br />

machine tools.<br />

Focus on core business<br />

For the EMAG Group, the sale of the shares is another important<br />

step in the implementation of the EMAG 2025 corporate<br />

strategy, according to managing director Dr. Mathias<br />

Klein: “The aim of our corporate strategy is to further expand<br />

our technological leadership in the machining of rotationally<br />

symmetrical components. We want to achieve this primarily<br />

by using interconnected digital machining systems and with<br />

data analysis to present our customers with the best overall<br />

result.” Commenting on the future of eldec, Dr. Klein explains,<br />

“as a result of the MBO, the transition to an independent<br />

company will take place smoothly, so there will be no restrictions<br />

for existing customers. We will continue to maintain<br />

a close business relationship with eldec, as many products,<br />

such as eldec’s excellent generator technology, are also<br />

used in the systems employed. We wish Mr. Rank and the<br />

eldec company continued success and look forward to joint<br />

projects in the future.”<br />

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

33.BI-MU<br />

Focus on five technological issues for five exhibition areas<br />

October 12 to 15, <strong>2022</strong>, the exhibition complex of<br />

fieramilano Rho will host 33.BI-MU, the major and<br />

most important Italian exhibition for the industry of<br />

metal cutting, metal forming and additive machine<br />

tools, robots, digital manufacturing and automation<br />

systems, enabling technologies and subcontracting.<br />

Promoted by UCIMU-SISTEMI PER PRODURRE, the<br />

Italian machine tools, robots and automation systems manufacturers’<br />

association, and organised by EFIM-ENTE FIERE<br />

ITALIANE MACCHINE, 33.BI-MU will take place one year<br />

after EMO MILANO, the world trade show of the sector,<br />

achieving resounding success with the public of reference.<br />

Owing to the extremely favourable economic moment,<br />

33-BI-MU will meet the consensus of the enterprises of the<br />

sector. At their disposal is a very dynamic and receptive<br />

Italian market, also thanks to the Government incentives<br />

which remain in force for the whole of <strong>2022</strong>.<br />

Willingness to invest in new production technologies, need<br />

for a renewal of industrial plants, which increasingly require<br />

state-of-the-art systems and machines, are the reasons for the<br />

33.BI-MU attraction.<br />

Besides machines and systems, 33.BI-MU focuses on 5<br />

technological issues for 5 exhibition areas representing the<br />

complete ecosystem of the sector: RobotHeart, sponsored<br />

by SIRI (Italian Robotics and Automation Association) and<br />

dedicated to the world of robotics; BI-MU Digital, focused<br />

on the world of ICT and connectivity technologies; BI-MU<br />


OF ADDITIVE TECHNOLOGIES and dedicated to additive<br />

technologies; METROLOGY & TESTING centered on systems<br />

and machines for testing, measuring and quality control<br />

and finally, BI-MU LOGISTICS, focused on the logistics for<br />

the mechanical industry.<br />

further information: www.ucimu.it<br />

24 no. 1, March <strong>2022</strong>

companies/fairs<br />

news & facts<br />

CHIRON Group and<br />

Greidenweis combine<br />

automation expertise<br />

Carsten Liske, CEO of the CHIRON Group SE, and<br />

Michael Greidenweis, owner and managing director<br />

of Greidenweis Maschinenbau GmbH & Co. KG,<br />

have set the course for a joint future. Greidenweis<br />

Maschinenbau is a 100 % CHIRON Group company<br />

since January <strong>2022</strong>.<br />

One of the CHIRON Group’s core competencies is turnkey<br />

solutions for machining processes based on machining and<br />

milling/turning centers of the brands CHIRON, STAMA and<br />

FACTORY5. The demand to automate turnkey solutions is<br />

continu ously increasing, as are the workpiece and industryspecific<br />

customer requirements. This applies to single-part<br />

production in tool manufacturing and precision technology<br />

as well as to series production in the mobility sector. The<br />

CHIRON Group’s product range meets the diverse automation<br />

tasks with integrated automation solutions, autonomous<br />

stand-alone solutions, the linking of machining centers and<br />

their process and system integration in assembly and production<br />

lines.<br />

Greidenweis is a system supplier for the automotive industry.<br />

In addition to its own development and assembly of<br />

machines and systems for laminating, joining and gluing,<br />

Greidenweis has positioned itself competently in process and<br />

system integration. For example the fully automated complete<br />

assembly of components for vehicle interiors using several<br />

processing stations. The 60-employee company has many<br />

years of experience in integrating various technical solutions<br />

into automated assembly systems and production lines,<br />

and has also successfully installed these in other industries.<br />

Greidenweis has developed its expertise in mechanical en-<br />

Successful takeover:<br />

the management teams of the CHIRON Group and<br />

Greidenweis are looking forward to the cooperation;<br />

left: Carsten Liske, CEO of the CHIRON Group SE;<br />

5 th from left: Michael Greidenweis, owner and managing<br />

director of Greidenweis Maschinenbau GmbH & Co. KG<br />

gineering and holistic automation solutions to a high level<br />

through consistently implemented overall process support –<br />

design with CAD/CAM and 3D technology, robot simulations,<br />

project control, manufacturing, assembly, commissioning<br />

and service.<br />

The CHIRON Group and Greidenweis will each concentrate<br />

on the further development of their traditional core<br />

businesses. With the strategic and operational cooperation,<br />

both companies also want to offer their customers attractive,<br />

future-oriented solutions through optimized and new combinations<br />

of products, competencies and know-how. The aim is<br />

to make machining, assembly and production processes even<br />

more efficient with innovative automation solutions. This<br />

applies to the process automation of large-volume components<br />

as well as to complex production lines from the blank<br />

through machining and associated processes to end-of-line<br />

testing.<br />

further information: www.chiron-group.com<br />

GrindingHub<br />

Planning work has started<br />

Over 260 companies had secured a place at<br />

GrindingHub as the registration phase drew to a<br />

close end of September. “We are more than satisfied<br />

with the number of registrations and are delighted<br />

with how GrindingHub is already set to become<br />

the new focal point for grinding technology,” says Dr.<br />

Wilfried Schäfer, executive director of the VDW<br />

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

The strong figures mean that the work can start work on<br />

the layout of three halls at the modern Stuttgart exhibition<br />

center – including the Paul Horn Hall which opened in 2018.<br />

Topical content, contemporary formats and<br />

a highly attractive trade show location<br />

GrindingHub will be celebrating its premiere in Stuttgart<br />

May 17 to 20, <strong>2022</strong>. With its international orientation<br />

and an attractive location that is easily accessible<br />

from all over the world, the event holds plenty of potential.<br />

The organizers are also part of a global network of associations<br />

throughout the well-known manufacturing nations,<br />

and have plenty of experience in organizing trade<br />

shows. The principal areas will be technology/processes,<br />

productivity, automation and digitalization in grinding<br />

technology. Two joint “GrindingSolutionPark” booths<br />

are also planned – demonstrating how science and industry<br />

can work hand-in-hand together. The GrindingHub<br />

web sessions will begin in the run-up to the event in spring<br />

<strong>2022</strong>. These proved their worth during the METAV digital<br />

and will now serve to whet visitors’ appetites for the new<br />

leading trade fair for grinding technology – encouraging to<br />

attend the fair in Stuttgart and meet exhibitors.<br />

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

no. 1, March <strong>2022</strong><br />


processes<br />

Production systems and manufacturing technologies<br />

for chassis and powertrain of rail vehicles<br />

authors: Manfred Berger, MAG IAS and Leo Schreiber, BOEHRINGER<br />

The European companies of the FFG Group serve<br />

the production companies and maintenance works for<br />

chassis and drive of rail vehicles with optimal products<br />

and manufacturing technologies. A team of successful<br />

specialists with many years of “Rail” industry experience<br />

guarantee high quality and the best economy<br />

with the most modern manufacturing solutions (machine,<br />

technology and peripherals) for the respective<br />

compo nent processing. The systems operate in the area<br />

of maxi mum availability with the appropriate component<br />

and process flexibility for the special tasks. The<br />

design of complete production systems and delivery<br />

of turnkey projects for single and series production by<br />

the system supplier and integration partner MAG as<br />

well as global service coverage with our own technicians<br />

is the key to a high degree of utilization and cost<br />

efficiency. In close cooperation with planning, project<br />

execution and production support, the operator can<br />

use the “Digital Factory” to help shape the successful<br />

implementation.<br />

FFG Group has a complete product portfolio which covers all<br />

processes for the production of prismatic and rotary components<br />

such as: milling, drilling, turning, grinding and gear<br />

cutting for the respective manufacturing task for the chassis<br />

and drive of rail vehicles. The expertise and product portfolio<br />

are available in the individual companies and thus the customer<br />

can be promised an optimal solution for the specific<br />

component processing (figure 1) within the group. The system<br />

supplier MAG (production locations: Germany, Hungary,<br />

USA, India and China) with professional project management<br />

is the coordinator with the competence for factory<br />

planning and supplying of turnkey systems.<br />

1: Individual technology experts for the machining of<br />

chassis components and delivery of turnkey systems<br />

(Bogie: presentation of the company TURBOSQUID)<br />

Chassis frames and large structural components<br />

There are two machine concepts available for the size of a<br />

chassis frame, both of which have a swivel spindle head. The<br />

swivel spindle offers an ideal solution for the structurally restricted<br />

access to the machining point. The gantry type milling<br />

center EVER5 (X / Y / Z: 9,500 / 4,000 / 1,250 mm) from<br />

JOBS (figure 2) with two work areas (fixture nests) on the<br />

table can be loaded and unloaded alternately, parallel to the<br />

main time, without interrupting processing. The traveling<br />

column machine THOR (X / Y / Z: 6,000 / 1,200 / 2,000 mm)<br />

from SACHMAN is equipped with a KOSMO milling<br />

head with a spindle speed of 4,000 rpm. With this solution,<br />

2: Machining of the undercarriage frame (bogie) with<br />

swiveling work spindles on a horizontal milling machining<br />

center THOR from SACHMAN (left) and a<br />

gantry milling center EVER5 from JOBS<br />

workpiece supply can also take place at the same time as the<br />

use of a second W-axis feed unit with an integrated B-axis rotary<br />

table in shuttle mode. The W-axis enables the workpiece<br />

to move towards the tool, particularly in the case of heavy<br />

and high-precision machining, and thus avoids a corresponding<br />

overhang on the tool side by moving out the Z-axis. Both<br />

machines can change the machining heads automatically and<br />

change tools via a sufficiently dimensioned tool magazine for<br />

complete machining of the bogies.<br />

Machining of cubic housing components and<br />

turnkey production systems<br />

The system competence for planning and execution of the<br />

FFG group is represented by the MAG brand. With its own<br />

product portfolio of special machines and CNC machines including<br />

process and equipment for machining, assembly and<br />

measuring stations, system automation (gantry loader or robot)<br />

and purchased systems, MAG supplies individual machines<br />

and production systems for the series production of<br />

housing components, e.g. cylinder blocks, cylinder heads,<br />

26 no. 1, March <strong>2022</strong>

processes<br />

3: Production line (pre-machining) for V8 to V20 cylinder<br />

crankcases for automatic series production by MAG with<br />

technology, tools, fixtures and loading gantry<br />

(component: CATERPILLAR Mapleton),<br />

workpiece: max. 4,500 kg raw, 4,100 kg finished<br />

transmission cases, housings for e-drives, as well as complete<br />

turnkey systems for these components, according to the respective<br />

customer specification (figure 3). An experienced<br />

team of project managers is available to coordinate the project<br />

and all co-suppliers. For project execution the latest software<br />

tools for the Digital Factory will be applied, e.g.: for the process<br />

design and optimization of the machining programs the<br />

virtual reality simulation is used. Simulation models are already<br />

created in the mechatronic design phase, with which<br />

virtual commissioning of the products and processes can<br />

be started even before the real system is built (figure 4). In<br />

cooperation with the suppliers of special and peripheral machines<br />

as well as automation, the commissioning of the functions<br />

of a production system can be carried out on a virtual<br />

model without erection of the real units in one common location<br />

and in higher quality, lower costs and shorter delivery<br />

times compared to conventional project management. These<br />

models are also available to the customer as a demonstrator<br />

for training operators and maintenance personnel. In addition<br />

to the digital product twins, the digital process twin for<br />

processing sequence and digital system twin, which optimize<br />

the system for the desired availability and prove it on the<br />

simulation model, are created in the proposal phase.<br />

table:<br />

Assignment of the components to the<br />

respective processing machines<br />

Vertical machining of rotary components<br />

and housings<br />

For the vertical machining of disc-shaped components such<br />

as railway wheels and brake discs, HESSAPP, with its many<br />

years of experience, offers a wide range of process knowledge<br />

for all core processes and optional technologies (ceramic<br />

components, lasers, hardening, grinding) for several<br />

complete series of turning machining centers (table). The<br />

VDM series with sizes 550 to 1,600 mm is used for wheels and<br />

brake discs. With a maximum turning diameter of 1,600 mm<br />

(swinging diameter 1,800 mm), an output of 165 kW and a<br />

payload of 2.5 t, wheels with all material specifications (ER<br />

6 to ER9) – regardless of the area of application of the wheels<br />

(freight, metro or high speed) – can be rough and finish machined<br />

with highest quality on the VDM 1600 machine with<br />

a capacity of 48 tool positions (figure 5). The VDM 1000 machine<br />

is an economical counterpart for smaller wheels with a<br />

turning diameter of up to 1,150 mm.<br />

The DVH 750 turning machining center and the DVT<br />

750 transfer machining center are ideal for self-loading and<br />

pick-up machines of brake discs up to workpiece diameter<br />

of 750 mm. With the integrated workpiece change from the<br />

4: Hardware-in-the-Loop (HiL) – test setup for<br />

virtual commissioning (VIBN) of the digital product twin<br />

5: Power pack VDM 1600 – vertical turning machine for<br />

wheel machining as a manufacturing cell (top right) or<br />

manufacturing system for the production of<br />

ready-to-install wheels (bottom – Lucchini, CAF)<br />

no. 1, March <strong>2022</strong><br />


processes<br />

infeed conveyor through the movable work spindle and delivery<br />

of the machined workpiece to the outfeed conveyor,<br />

both machines are more comparable to a production cell<br />

without additional investment in automation. The transfer<br />

machine HESSAPP DVT 750 is a compact vertical turning<br />

cell for two-sided complete machining. With the two turning<br />

spindles, extensive and qualitatively demanding features<br />

can be machined on the workpiece. The technological capabilities<br />

of the HESSAPP DVT 750 thus make it possible to<br />

dispense a subsequent station to complete the processing. A<br />

standing, stationary and a movable, hanging spindle machine<br />

both sides on two workpieces in the machine in parallel operation<br />

and transfer the workpieces without additional equipment<br />

(figure 6).<br />

maximum vibration damping as the basis for the finest surface<br />

quality, extended tool life and thus reduced tool costs.<br />

With the process know-how of the BOEHRINGER turning<br />

specialists, these robust, durable and high-precision<br />

machines produce grinding qualities when required.<br />

The horizontal and vertical CNC lathes of the brands<br />

HESSAPP and BOEHRINGER are intended for integration<br />

in complete production systems (figure 8) and can be ideally<br />

integrated into an automation concept with the interfaces<br />

provided and can be loaded and unloaded fully automatically<br />

from above and from the front. The supply and disposal of<br />

the machines (swarf and suction) can be configured either<br />

centrally or decentralized. For maximum indispensable<br />

6: The unbeatable machine and processing concept of<br />

the HESSAPP DVT 750<br />

Horizontal machining of shafts and axes<br />

The powerful horizontal CNC lathes of the VDF series from<br />

BOEHRINGER are designed for hard machining and highest<br />

component quality. With frame sizes VDF 450 and 650,<br />

all requirements for the wheelset axles and drive shafts can<br />

be covered and the required processes (rough turning, fine<br />

turning, milling, gear cutting and other machining with<br />

driven tools, like drilling, threading, milling) can be covered<br />

(figure 7). The machines are built on hydropol beds for<br />

maxi mum mechanical and thermal stability. This achieves<br />

8: Production plant for ready-to-install drive shafts of<br />

high-speed rail vehicles (turnkey)<br />

availability within an automated manufacturing system, the<br />

accessibility is designed for the shortest service interventions.<br />

The parts and components used meet the high production<br />

demands of a three-shift operation of up to 18/19 shifts per<br />

week with a service life of > 15 years and the permanent machining<br />

accuracy.<br />

The product MORARA MT 2500 HD (figure 9) for sha ft<br />

components with a length of 2,600 mm(3,000; optional)<br />

and a weight of up to 2 t is available from FFG’s Grinding<br />

7: Horizontal lathe BOEHRINGER VDF 450-4 T with a<br />

max. turning length of 3.4 m; main and counter spindle each<br />

with A11 chuck, 2 x 56 kW drive power, 2 x 3,486 Nm @ 40 %<br />

9: MORARA MT 2500 HD CNC grinding machine with<br />

two hydrodynamically mounted grinding units for<br />

complete machining of wheel axles in one clamping<br />

28 no. 1, March <strong>2022</strong>

processes<br />

Solutions division for the finest machining of axes and shafts.<br />

The machine is particularly characterized by its productivity<br />

and process flexibility, as well as its high energy efficiency<br />

and compact footprint. Like all FFG machines for integration<br />

in production lines, loading from the front and top can be<br />

carried out fully automatically or manually (stand-alone).<br />

With a maximum grinding diameter of 350 mm and two<br />

grinding units (optional) on high-precision slide and feed<br />

units, driven by linear motors, the axles and drive shafts for<br />

rail vehicles can be finished in one clamping.<br />

The thermal control of all machine assemblies including<br />

the linear drives through their integrated cooling circuits,<br />

ensures the high-precision machining level of the machine<br />

and is supported by the hydrodynamic bearings of the selfbalancing<br />

grinding spindles with a 46 kW drive power (up to<br />

50 m/s circumferential speed of the wheels) and the resulting<br />

long service life. With a B-axis for the right grinding unit,<br />

conical areas on the workpiece can also be machined in the<br />

range +/- 5 ° with a resolution of 0.0001 °.<br />

Turning and gear hobbing wheels and pinions<br />

Vertical lathes of the brands HESSAPP and SMS are suitable<br />

for machining the gearwheels in the powertrain of the<br />

driven vehicles. The gear cutting machines from MODUL H<br />

600 to H 2300 are designed for the series production of large<br />

gears up to m < 28 and workpiece diameters up to 2,400 mm.<br />

The machines can be used for all hobbing and form milling<br />

processes for soft machining as well as for the finished<br />

machining of hardened gears. In addition to spur gears, helical<br />

gears, spherical or conical gears can be manufactured<br />

using hardware and software options as well as shafts with<br />

multiple gears, worm gears and other special profiles. The<br />

MODUL H 600 to H 800 series is loaded with the integrated<br />

ring loader. The larger machines are linked with classic<br />

automation systems (e.g. portal loaders, robots, etc.). In accordance<br />

with the high machining forces and stresses<br />

involved in the manufacture of gears, the large MODULE H<br />

900 to H 2300 series features box ways with coating.<br />

Wheelset machining for maintenance<br />

The machining of vehicle wheelsets for the service is becoming<br />

increasingly important. Recent studies [1, 3, 4] do recommend<br />

the machining of the wheels at each service stop (approx.<br />

70,000 km) with a material removal of 1 mm compared<br />

to the previous condition-based reworking of the profiles<br />

with a material removal of 4 - 5 mm. The elimination of<br />

surface defects in the rolling contact area that begin with fatigue<br />

crack formation are the new approaches to significantly<br />

reduce maintenance costs in connection with a possible<br />

doubling of the service life to up to km 1.6 million mileage [2] .<br />

In addition to special machines for turning wheelsets in an<br />

installed (underfloor lathes) or removed (above-floor gantry<br />

machines) condition, CNC lathes such as the BOEHRINGER<br />

VDF DUS 800/1000/1110 (turning length 820 to 1,110 mm<br />

above bed, figure 10) up to size VDF 1300/1500/1600 DUS<br />

(1,300 to 1,600 mm above bed) are also available for the repair<br />

shop for smaller series. A highlight of the series are the hardened<br />

double prism guides with scraped guide surfaces on the<br />

slide, which are the basis for the high and durable machining<br />

accuracy and highly economical production.<br />

10: Horizontal CNC lathe BOEHRINGER VDF 1110 DUS for<br />

machining wheelsets for profiling the wheels and<br />

machining the brake disc surfaces<br />

FFG Group offers itself as an ideal partner with the wide<br />

range of manufacturing machines for different technologies<br />

in the area of drives and running gear for rail vehicles. Due<br />

to the turnkey system competence, peripheral systems up to<br />

complete production plants can be planned and handled. In<br />

close cooperation with the plant operator, the appropriate<br />

technologies from the partly overlapping product portfolio<br />

are selected in the planning phase, taking customer preference<br />

into account, and the most cost-effective solution for<br />

high productivity is worked out with regard to the required<br />

flexibility of the technologies, component bandwidth and<br />

production volume. With globally available efficient service<br />

and a special memorable training program for operators<br />

and maintenance personnel, the robust and durable products<br />

unfold their full efficiency using the latest technologies.<br />

References<br />

[1]<br />

Boudnitski, G., Edel, K.-O.:<br />

Oberflächendefekte im Scheibenbereich,<br />

Abschlussbericht zum DFG-Projekt,<br />

Brandenburg an der Havel, April 1998<br />

[2]<br />

Müller, R. et al.:<br />

Definition on wheel mainenance measures for reducing<br />

ground ibration,<br />

EU FP7 project RIVAS, SCPO-GA-2010-265754,<br />

November 2013<br />

[3]<br />

Alstom:<br />

Technical specification wheel wear analysis,<br />

CCN-WR-Analysis, December 22, 2003<br />

[4]<br />

Muhamedsalih, Y., Stow, J., Bevan, A.:<br />

Use of railway wheel and damage predicitions tools to improve<br />

maintenance efficiency through the use of economic<br />

tyre turning (ETT),<br />

Institute of Railway Research, University of Huddersfield,<br />

UK; in: Journal of Rail and Rapid Transit, July 2010<br />

further information: www.mag-ais.com<br />

no. 1, March <strong>2022</strong><br />


processes<br />

Intelligent generating grinding – quality assurance<br />

for e-transmission gears already on board<br />

Transmissions for electric cars are much simpler<br />

in design than for conventional combustion engines,<br />

but place far higher demands on the manufacturing<br />

precision of the gears used. Thanks to completely new<br />

procedures for quality assurance directly in the final<br />

machining process, which is gear grinding, these specifications<br />

can also be met in series production.<br />

All-electric vehicle drives usually make do with two-stage,<br />

non-shiftable transmissions. One would have thought that<br />

this would greatly simplify production. After all, this type of<br />

transmission design has just four gears, distributed between<br />

the drive shaft, the second stage with fixed gear and intermediate<br />

shaft, and the axle drive gear. But in reality, it’s not that<br />

simple: first of all, engine speeds are much higher for the e-<br />

drive than for combustion engines, at up to 16,000 rpm. This<br />

means electric motors deliver an almost constant torque over<br />

a wide speed range. Unlike combustion engines, it is applied<br />

to the transmission right from zero speed.<br />

Furthermore, there is an additional constraint that makes<br />

production much more demanding than with the conventional<br />

drive train, as Friedrich Wölfel, head of machine sales<br />

at Kapp Niles, describes: “The noise from a combustion engine<br />

masks the transmission noise, meaning it is not noticed<br />

in the first place. On the other hand, an electric motor<br />

is almost silent. Above about 80 km/h, rolling noise and wind<br />

noise are the predominant sounds, irrespective of the drivetrain.<br />

But below that speed, transmission noise can be irritating<br />

in electric vehicles. We also have to take that into account<br />

when manufacturing gears.”<br />

Of course, the flank load capacity of the gears and good<br />

running properties are also of paramount importance with<br />

e-drives. However, the almost constant torque level and the<br />

high speeds require a different gearing design, which in turn<br />

can affect the noise dynamics. Here, in particular, demands<br />

are higher than with combustion engines.<br />

However, when it comes to the pressure to generate maximum<br />

efficiency, there is no difference at all between gears for<br />

e-vehicles and conventional drives. Accordingly, the highly<br />

productive generating grinding process is also generally used<br />

as a fine machining process in the series production of e-<br />

transmission gears.<br />

The challenge for Kapp Niles, as a specialist in hard fine<br />

machining of gears, is to implement a generating grinding<br />

process that is both productive and, above all, optimised in<br />

terms of noise dynamics.<br />

Hot on the heels of transmission noises<br />

Achim Stegner, head of predevelopment at Kapp Niles,<br />

describes the basics: “Depending on the modifications of<br />

the gearing defined at design stage, such as line corrections,<br />

width convexity, head retraction, as well as the profile and<br />

line interlocks typical of the process, characteristic noises<br />

occur in the transmission during meshing, which can be<br />

30 no. 1, March <strong>2022</strong>

processes<br />

figure 1<br />

Tolerance corridors for closed loop<br />

assigned to specific tooth meshing frequencies. The entire<br />

transmission, in turn, also exhibits characteristic properties<br />

with regard to structure-borne noise and radiation, depending<br />

on the constructive design. This is stimulated in the tooth<br />

meshing frequency and its multiples. Manufacturers try<br />

to minimise this effect as much as possible by adapting the<br />

design of transmission and gears.”<br />

For the time being, these considerations only apply to “perfect”<br />

gearing. But of course, like any other mechanical component,<br />

gears also generate variances from the ideal target<br />

geo metry in series production. These have different causes<br />

and effects, as Achim Stegner explains: “In addition to the<br />

stimulation caused by the tooth mesh, there are other disturbance<br />

variables that can result in noises in the tooth mesh.<br />

These make themselves felt as ‘ghost frequencies’. These are<br />

frequencies that do not coincide with the tooth meshing frequencies<br />

and their multiples, and can just be introduced<br />

into the component during grinding.” Ghost frequencies are<br />

caused by minimal irregularities that are almost impossible<br />

to completely avoid in series production. It becomes particularly<br />

critical when these variances map almost exactly onto<br />

the circumference of a gear, as this results in harmonic stimulation.<br />

It takes a lot of expertise and process experience to<br />

recognise the reasons for such irregularities and, if possible,<br />

to avoid them in the first place.<br />

The cause of such malfunctions can be found, for example,<br />

in the axis drives of the machine tool used. Electric motors<br />

have certain pendulum moments. Measuring systems work<br />

with discrete line counts and finite eccentricity errors from<br />

assembly. Last but not least, balance condition and spindle<br />

bearings can contribute to possible irregularities. Waviness as<br />

small as 0.1 mm can cause noise in gears. Achim Stegner explains<br />

some more causes: “Every machine has natural vibrations.<br />

For example, the typical natural frequency of a workpiece<br />

spindle is about 250 Hz. This can also be reproduced<br />

exactly on the workpiece if the speed constellation in the generating<br />

grinding process is unfavourable. We can eliminate<br />

such effects by the clever choice of a suitable speed window<br />

during machining.”<br />

Once the optimisation potential on the machine side has<br />

been exhausted, there are also a number of technological<br />

options for improving component quality in terms of noise<br />

dynamics. These include, for example, the selection of the<br />

number of gears of the grinding worm, the speed ratio during<br />

dressing and grinding, the finishing speed and the feed rate.<br />

Not all errors are the same<br />

Roughly speaking, there are two typical types of error patterns<br />

in serial gear grinding: on the one hand, trends are<br />

emerging that show a continuous change in characteristics.<br />

On the other hand, there are individually conspicuous components.<br />

Trends are usually easier to control. They can be<br />

caused, for example, by the gradual wear of a grinding worm.<br />

If permissible manufacturing tolerances are exceeded here, it<br />

is usually sufficient to shorten the cycle between two dressing<br />

processes. They can also be easily recognised during component<br />

testing by a gradual approach of the measured values to<br />

the tolerance limit.<br />

Component-specific defects, on the other hand, are unpredictable.<br />

They become noticeable through sudden deviations<br />

in one or even several quality criteria. This can be caused by<br />

grinding worm chipping, workpiece blank errors or set-up<br />

errors.<br />

Since the actual machining of a gear takes much less time<br />

than the control measurement in highly efficient manufacturing<br />

processes such as generating grinding, it is also not<br />

possible to inspect every single component. In addition, as<br />

no. 1, March <strong>2022</strong><br />


processes<br />

described at the beginning, quality demands for gears for<br />

e-transmissions are extremely high. “The required tolerances<br />

of profile angle, flank line angle, concentricity, two-ball dimension<br />

are in some cases smaller than in the conventional<br />

drive train by a factor of 3. For the flank line angle error<br />

fHß, a typical requirement is ± 4 mm; with combustion engine<br />

transmissions, this was sometimes ± 13 mm,” says Friedrich<br />

Wölfel, describing the requirements of his customers.<br />

Together with the required machine and process capabilities,<br />

these quality requirements are testing the limits of what<br />

is technically and economically feasible. And the static and<br />

dynamic stability of the processing machine and process cannot<br />

be increased at will. The only way out is to start with the<br />

methods of analysis and control. Because otherwise: the narrower<br />

the tolerance limits become with the same machine/<br />

process capability, the greater the number of measured components<br />

must be. However, this involves a great deal of effort.<br />

And ultimately, downstream component testing does not add<br />

value either.<br />

With regard to the approach to trend-related deviations<br />

from the target geometry in particular, the ‘closed loop’ has<br />

already established itself as an important tool. This accelerates<br />

and improves the feedback between downstream gear<br />

measurement and the processing machine itself. Here the results<br />

of the inspection on the measuring machine are no longer<br />

printed out and made available to the machine operator<br />

on paper for evaluation, but are transmitted directly to<br />

the processing machine as a standardised file. The grinding<br />

machine then uses preselectable tolerance corridors to decide<br />

independently whether it needs to intervene in the process<br />

at all, for example with scalable correction values. If unexpectedly<br />

high variances from the target geometry occur,<br />

the decision on how to proceed is then up to the operator<br />

themselves (figure 1).<br />

The referee at the end of the<br />

manufacturing process<br />

At the end of the manufacturing process of a complete transmission<br />

is what is known as an ‘end-of-line test bench’. It is<br />

no longer just individual gears that are tested here with regard<br />

to their quality, but fully assembled transmissions are<br />

evaluated. They go through various test cycles that simulate<br />

operating conditions in an actual vehicle. The operating noise<br />

is also recorded. Acousticians can analyse this data to extract<br />

intervention ratios, typical frequencies and possible interfering<br />

noises. “Unfortunately, this also means that gearing defects<br />

are only noticed at the end of the manufacturing process,”<br />

complains Friedrich Wölfel. “The complete transmission<br />

must then be dismantled, the individual components<br />

checked and, based on this, analysed to determine which<br />

component is responsible for the anomaly on the test bench.<br />

It could also be that a complete batch of components can<br />

cause problems. But that only becomes apparent when the<br />

entire value chain has already been completed.”<br />

Today it is possible to identify components that could cause<br />

noise before they are installed in the transmission. A very<br />

common procedure for e-drives is the waviness analysis on<br />

gear surfaces. Here, profile, line and pitch measurements are<br />

carried out on all teeth on the gear measuring machine and<br />

lined up in such a way that the gear is mapped over its complete<br />

circumference. The waviness on the gear wheel can be<br />

mathematically measured. However, starting with the complete<br />

measurement of the gears, this procedure is very timeconsuming<br />

and thus unsuitable for testing every single piece<br />

in series production. Friedrich Wölfel on this: “The grinding<br />

time of typical e-transmission components is less than<br />

one minute, whereas the measuring time is four to six minutes;<br />

indeed, in the case of an all-tooth measurement as the<br />

basis of a waviness analysis, it can be significantly more. And<br />

ultimately, downstream component testing does not add<br />

value either. What is needed here is further development of<br />

in-process analysis, which allows conclusions to be drawn<br />

about the component quality produced during the machining<br />

itself.”<br />

Identify possible noise problems<br />

at the machining stage<br />

A promising approach is indeed to detect possible defects as<br />

early as the grinding process. Process monitoring is the buzzword.<br />

Achim Stegner explains the approach: “We already<br />

have numerous sensors and measuring systems in the machine<br />

that can provide us with many indications, measured<br />

values and information. At the moment, we primarily use it<br />

only to operate the functions of the machine. In the future,<br />

however, we also want to use it to assess the machining process<br />

directly in the machine.”<br />

figure 2<br />

Error analysis and index calculation in the machining process<br />

32 no. 1, March <strong>2022</strong>

processes<br />

However, this does not mean integrating<br />

an additional tactile measuring<br />

function into the grinding machine<br />

in order to achieve a faster closed loop.<br />

Nor is it a question here of inspecting a<br />

ground component directly in the machine,<br />

evaluating it and correcting any<br />

discrepancies during the production of<br />

further components. The focus is rather<br />

on analysing the machining process<br />

in real time (!) in order to detect deviations<br />

from a previously defined reference<br />

process. However, it is not enough<br />

to only define envelopes for signals<br />

from the machine to do this. This can<br />

be explained using the “power consumption<br />

of the grinding spindle” signal<br />

in figure 2 as an example. This signal<br />

can be used to detect a possible<br />

flank line angle error (fHß) at an early<br />

stage. Stegner: “However, the procedure<br />

via envelope detection reaches its limits<br />

here, as the error is difficult to iden -<br />

tify. As long as the signal remains within<br />

the envelope, no alarm gets triggered.<br />

So you need a more intelligent form of<br />

evaluation. An artificial intelligence<br />

that attempts to emulate human decision-making<br />

structures. This involves<br />

making decisions based on a multitude<br />

of different information – overlaid with<br />

the person’s own experiences – upon<br />

which they act.<br />

Process monitoring:<br />

intervene before it’s too late<br />

Process monitoring can be defined as<br />

component-specific monitoring and<br />

evaluation of the grinding process. As<br />

described, it is not a trivial matter to<br />

generate an action instruction from the<br />

sensor signals. But it is possible. Various<br />

characteristic values can be formed<br />

from time signals. In the simplest case,<br />

these can be maximum or RMS (root<br />

mean square) values of the signals. The<br />

characteristic values are then combined<br />

with the known project data via algorithms<br />

and processed into indices, for<br />

example a noise or screw breakout index.<br />

Achim Stegner explains about trans -<br />

mission noises specifically: “An order<br />

analysis similar to the order spectrum<br />

on an end-of-line test rig can be created<br />

for noise-critical components via an<br />

FFT (fast fourier transformation). This<br />

makes it easier to classify the recorded<br />

signals and relate them to results on the<br />

transmission test bench (see figure 3).<br />

figure 3<br />

Order spectrum, recorded on a transmission test bench<br />

Measurement data that is not processed is of no use.” In the end, especially in the<br />

manufacturing environment, only appropriate indices help to identify errors very<br />

specifically.<br />

The benefits of process monitoring can therefore be seen<br />

in the following points:<br />

→ 100 % testing of all components<br />

→ identification of anomalies while still in the grinding process<br />

→ detection of component-specific faults<br />

→ targeted reporting of irregularities<br />

→ adaptive intervention in the process<br />

→ parts tracing<br />

Next step: standardisation<br />

Process monitoring is not yet an app that you can simply download and use.<br />

Rather, it is a customer- and application-specific development that defines and<br />

monitors indices in relation to the respective component. But even this first step is<br />

far more than was considered feasible until only recently. Achim Stegner on this:<br />

“Several pilot customers are already using this functionality today. We are already<br />

able to detect different errors and intervene on the process side. In addition, we are<br />

already working on having the grinding machine teach itself characteristic values<br />

for new components. However, this of course requires broad empirical knowledge<br />

from error patterns, the geometric quality of the components and corresponding<br />

feedback from the transmission test bench.” Friedrich Wölfel adds:<br />

“The next goal is that the user can also use this functionality without our component-specific<br />

support. It is also important to understand that process monitoring<br />

and closed loop are not contradictory, but complementary.”<br />

Both approaches to process-integrated quality assurance are already available<br />

for Kapp Niles machines today and are continuously being given further functional<br />

scopes and utilisation options through the experience gained from series<br />

production.<br />

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

no. 1, March <strong>2022</strong><br />


processes<br />

Flexibility, transparency and cost savings<br />

BMR elektrischer und elektronischer<br />

Gerätebau GmbH is now presenting<br />

MotorView to the trade public for the first<br />

time at GrindTec <strong>2022</strong>.<br />

This measuring system can very sensitively record<br />

the current load status of converter and<br />

motor in a drive system and display it graphically<br />

and numerically on its separate display.<br />

As usual with BMR, the focus is on easy operation<br />

and installation. MotorView is simply<br />

“looped” into the motor cable between the inverter<br />

and the spindle. This makes it possible<br />

to use and retrofit the measuring system in any<br />

grinding machine with a<br />

converter-motor<br />

combination up<br />

to 400 V voltage<br />

and 20 A<br />

current.<br />

MotorView<br />

can be used<br />

to graphically<br />

display and<br />

monitor the<br />

grinding process<br />

as well as<br />

to control the<br />

efficiency of<br />

the converterspindle<br />

unit.<br />

Depending on<br />

the version, it<br />

provides precise<br />

data on the voltage<br />

and current of the<br />

individual motor<br />

phases as well as the<br />

current rotational frequencies.<br />

This enables the machine operator to detect,<br />

for example, whether his system is poorly parameterized,<br />

control oscillations are occurring<br />

or the spindle is being operated with a voltage<br />

that is too high for the currently set speed. This<br />

saves operating costs and prevents possible failures<br />

due to maintenance or tool damage.<br />

As an interface to machine control the<br />

same digital and analog inputs and outputs<br />

are available as with the DressView dressing<br />

system. This has already been presented by BMR<br />

in 2018 at GrindTec and has since proven itself<br />

in practice in many applications. It remains<br />

the only system on the market worldwide that<br />

enables sensorless grinding and dressing from<br />

a single source.<br />

Furthermore, two newly developed frequency<br />

converters await visitors at the BMR-booth.<br />

SFU 1000 for small and medium-sized milling<br />

and grinding machines as well as for all CAD/<br />

CAM systems with high-speed drives. With<br />

an increased output current of 12 A, it can also<br />

drive larger spindles with higher current requirements<br />

and this at 55 V ac output voltage.<br />

With a very compact size, comparable to a<br />

cigarette box, the SFU 400 can drive AC and<br />

BLDC motors at speeds up to 100,000 rpm. It is<br />

of particular interest to manufacturers of CAD<br />

machines or spindles in the miniature range,<br />

and can be accommodated in any housing and<br />

application.<br />

GrindTec <strong>2022</strong>, hall 1, booth 1067<br />

further information: www.bmr-gmbh.de<br />

34 no. 1, March <strong>2022</strong>

processes<br />

CNC chamfering<br />

The ideal process for every need<br />

Chamfering gears prevents the edges of the teeth<br />

from becoming brittle during heat treatment and<br />

reduces transportation and installation damage. Multiple<br />

processes can be chosen for this. Classic technology<br />

such as press deburring or chamfering with end<br />

mills are increasingly being superseded by CNC controlled<br />

processes such as ChamferCut and FlexChamfer.<br />

These are extraordinarily economical and guarantee<br />

an excellent chamfer quality which can be reproduced<br />

very precisely. CNC controlled processes are<br />

easy to operate and minimize set up cost.<br />

Liebherr knows the advantages and the limits for the various<br />

processes and individually advises customers with their selection.<br />

Requirements for an optimal chamfering process can<br />

be individually arranged by batch size, chamfer shape, subsequent<br />

machining or component geometry. Liebherr specializes<br />

in particular in the ChamferCut technology from<br />

LMT-Fette. As a pioneer in introducing this process and its<br />

development to being production-ready, Liebherr is determined<br />

to take this further in the future: by consulting with<br />

clients, both companies are working to improve precision,<br />

productivity and usability.<br />

ChamferCut –<br />

precise, quick and reliable<br />

◆ precise chamfering geometry and quality,<br />

no material deformation<br />

◆ can be reproduced very precisely<br />

◆ easy operation, short setup times due to CNC control system<br />

◆ single-cut strategy: no additional finishing cut<br />

required to remove bulging on the lead<br />

◆ low investment cost and long tool life<br />

◆ ideal for subsequent finish machining<br />

◆ integrated chamfering device or standalone<br />

machines from Liebherr enable parallel machining<br />

◆ application range module 0.5 - 36 mm<br />

ChamferCut CG (collision gear) –<br />

chamfering despite interfering contour<br />

◆ deburring the tooth space to the tooth root surface,<br />

even on interfering contours chamfering including<br />

the root, even for collision critical<br />

◆ more degrees of freedom with the chamfer divided<br />

between the left and right profile<br />

◆ can be implemented on Liebherr machines<br />

with a simple software update<br />

◆ batch sizes: suitable for medium and<br />

large-scale production<br />

→ application examples:<br />

truck shafts, passenger vehicle idle gears and<br />

ring gears, industrial gearboxes<br />

ChamferCut<br />

ChamferCut IG (internal gear) –<br />

chamfering of internal gears<br />

◆ chamfering of internal gears on both flanks in one cut<br />

◆ machining on compact standalone machine, e.g. LD 180 C<br />

→ application examples:<br />

internal gears of plantenary and e-motive gearboxes<br />

FlexChamfer –<br />

maximum flexibility for external and internal gears<br />

◆ CNC controlled advanced development of<br />

chamfering with end mills<br />

◆ development of variable chamfering forms<br />

with standard catalog tools<br />

◆ particularly suitable for external gears with or<br />

without interfering contours as well as<br />

shafts and internal gears<br />

◆ use in hobbing, shaping and gear skiving machines<br />

◆ parallel to machining (depending on the<br />

main machining time)<br />

◆ ideal for small and medium batch sizes<br />

→ examples of use:<br />

stage planetary gears, double internal gears<br />

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

no. 1, March <strong>2022</strong><br />


machining center<br />

Tornos: a source of strength to<br />

medical device manufacturers around the world<br />

Few industries are as regulated – or as associated –<br />

with the need for quality, safety and transparency, as<br />

the global medical device manufacturing sector. And<br />

no partner is more committed to advancing medical<br />

device and instrument manufacturers’ precision,<br />

quality and return on investment than Tornos. For<br />

more than 30 years Tornos has closely collaborated<br />

with medical device manufacturers worldwide to<br />

help them deliver impeccable products that improve<br />

patients’ quality of life. The company’s medtech leadership<br />

was underscored this autumn when MEDTECH<br />

OUTLOOK magazine named Tornos as a recipient<br />

of its Top Medical Device Manufacturing Companies<br />

in Europe 2021 award. The annual listing honors ten<br />

companies at the forefront of providing medical device<br />

manufacturing and impacting the industry.<br />

Headquartered in Switzerland and boasting a global footprint,<br />

automatic turning machine manufacturer Tornos<br />

is a pioneer of sliding headstock technology or Swiss-type<br />

automatic lathes. Because the high-precision turning sector<br />

is subject to stringent standards governing quality, precision<br />

and productivity, it is little surprise that these Swiss strengths<br />

come from the same part of the world.<br />

SwissNano for flawless dental applications<br />

Tornos’ SwissNano is the champion for manufacturing<br />

small – even micro – medical and dental parts requiring very<br />

high precision. The machine’s unique kinematics enable turn -<br />

ing, drilling, cutting, deburring, roughing and finishing<br />

operations for the tiniest parts, whether simple or extremely<br />

complex. Behind the SwissNano is a machine concept delivering<br />

exemplary balance and thermal management allowing<br />

perfect results. This compact solution offers excellent accessibility<br />

for easy setup and can be used with a fixed/rotating<br />

guide bush – or no guide bush at all.<br />

With all those attributes – as well as superb energy efficiency<br />

that boosts its sustainability profile – it’s no wonder<br />

the global dental implants manufacturing leader this year<br />

purchased 45 SwissNano 7 machines for installation in its<br />

plants in Brazil, the United States and Switzerland.<br />

“The SwissNano 7 was chosen because of its precision,<br />

quality, return on investment, and our experience throughout<br />

the medtech value chain,” says Tornos CEO Michael Hauser.<br />

Vast experience throughout the medtech production<br />

chain, a holistic approach, a complete production<br />

program and a global presence make Tornos the perfect<br />

partner to medical device and instrument manufacturers<br />

and their suppliers.<br />

Moreover, thanks to experience across a broad range<br />

of industry segments – including medical & dental,<br />

automotive, micromechanics, and electronics – Tornos is<br />

uniquely positioned to partner with manufacturers, offering<br />

them support to deal with increasing product complexity,<br />

for example.<br />

Tornos offers manufacturers professional,<br />

specialist solutions in the very demanding field<br />

of medtech. To meet the industry’s needs, major<br />

technical advances are required. Tornos<br />

relies on its own technologies, quality, and<br />

medical & dental experience to create solutions<br />

that keep manufacturers at the frontier of medtech<br />

innovation.<br />

Tornos’ solutions for medical & dental range from the<br />

micro- and nano-precision Swiss-type SwissNano for<br />

dental applications such as implants and abutments; the<br />

Swiss-type SwissDECO for production of orthopedic nails;<br />

and the MultiSwiss multispindle machine solution for manufacturing<br />

long locking parts and screws for spine surgery.<br />

Tornos’ mastery<br />

of Swiss-type lathe<br />

kinematics ensures<br />

the flawless results dental<br />

implant manufacturers expect<br />

36 no. 1, March <strong>2022</strong>

machining center<br />

Tornos chief sales officer (CSO) Jens Thing further detailed<br />

the SwissNano 7’s direct benefits to manufacturers in the<br />

medical & dental sector.<br />

“Because the production of dental applications such as<br />

implants and abutments is subject to stringent standards<br />

governing quality, precision, and productivity, this model<br />

Swiss-type machine was selected. Behind the SwissNano<br />

series is a machine concept delivering exemplary balance and<br />

thermal management,” he says. “Our customer is able to<br />

boost productivity, reduce its costs per part, and produce<br />

perfect parts.”<br />

SwissDECO and<br />

MultiSwiss for perfect implants<br />

When it comes to implants – whether for dentistry or orthopedics<br />

– Tornos’ SwissDECO and MultiSwiss platforms<br />

deliver peerless productivity and quality.<br />

The multitasking SwissDECO range represents Tornos’<br />

vision of the future of the Swiss-type lathe. Its enhanced<br />

machining and <strong>tooling</strong> solutions make it superb for medtech<br />

applications. The compact SwissDECO enables highly productive,<br />

extremely precise and high-quality production of<br />

complex parts, thanks to its optimized programming tools<br />

and ideal ergonomics to speed up parts programming and<br />

shorten machine preparation and setup.<br />

Tornos has<br />

vast knowledge in the production<br />

of cancellous, cannulated and cortical bone screws<br />

At the same time, Tornos’ MultiSwiss platform makes it<br />

possible for manufacturers to quintuple their productivity<br />

and secure their position in medtech. From screws for facial<br />

surgery and spinal fusion to various implants, the easy-touse<br />

MultiSwiss consumes minimal floor space and boasts<br />

less tool wear and better surface finish than comparable solutions<br />

– all while allowing quicker reaction times, unique<br />

homogeneity of production results, and fast setup due to<br />

unique accessibility. In this way manufacturers can boost<br />

their productivity, reduce their costs per part, and produce<br />

perfect parts.<br />

Tornos’ solutions for<br />

medical & dental: SwissDECO<br />

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

no. 1, March <strong>2022</strong><br />


machining center<br />

Future of tool grinding<br />

“Dear tool grinders, don’t say later<br />

that you didn’t know”<br />

Only someone who is completely convinced of his<br />

new tool grinding machine is that confident when he<br />

speaks. Dirk Wember, managing director of Haas<br />

Schleifmaschinen in Trossingen, Germany, has revealed<br />

some interesting details about the new hightech<br />

tool grinding machine. “With the new Multigrind®<br />

Radical we’re making an offer to the industry<br />

to change the way we’ve been working and enter the<br />

future of tool grinding."<br />

As Dirk Wember reported, customers have been asking for<br />

years: please develop a high-tech grinding machine that is<br />

focused consequently on tool grinding. Until now, the Multigrind®<br />

CU was available in the portfolio. However, this hightech<br />

solution was intended for complex tools and not explicitly<br />

for fast, simple series production. For many customers,<br />

the universal grinding machine was simply too versatile. “On<br />

our Multigrind® CU, we now grind extremely complex freeform<br />

shapes, including medical products or gears. Of course,<br />

it is also possible to grind the absolutely perfect profile insert,<br />

or the perfect tap on the Multigrind® CU,” says Dirk Wember.<br />

New requirements demand a new fiction<br />

The requirements for the production of precision tools have<br />

grown significantly in recent years. The buzzwords here are:<br />

more precise tools, just-in-time production, lower quantities,<br />

very small batches from batch size 1 to 100, chaotic assembly<br />

and faster production. This significantly increases competitive<br />

pressure and requires greater flexibility in tool grinding<br />

with minimal non-productive time. A perfect fit for a hightech<br />

machine concept that leaves the beaten track behind.<br />

The designers and software developers at Haas<br />

Schleifmaschinen have said goodbye to all existing solutions<br />

on the market and have radically rethought their tool grinding<br />

machine and then realized it rigorously. Since the end<br />

of last year, there have been repeated indications that Haas<br />

Schleifmaschinen has developed a promising machine. And<br />

expectations among tool grinders are correspondingly high.<br />

“Anyone who knows Haas Schleifmaschinen knows<br />

we only develop something new if we can<br />

radically improve what we already have”<br />

“And better doesn’t just mean faster, easier, more flexible,<br />

more economical and more precise than comparable tool<br />

grinding machines. At the end of the day, these are just results.<br />

We want to transform tool manufacturing with our Multigrind®<br />

Radical,<br />

so it’s not<br />

about better,<br />

we’re starting<br />

a change. Of<br />

course, this is<br />

not done with<br />

The new Multigrind® Radical:<br />

the game changer for all tool grinders<br />

one machine<br />

alone. We have<br />

developed the basics for the game changer in our own software<br />

department. The perfect choreography between software<br />

and hardware is crucial. And we have succeeded excellently<br />

in this.”<br />

Haas Schleifmaschinen is not a traditional grinding<br />

machine manufacturer. For around 30 years, the high-tech<br />

machines have been operated using the company’s own<br />

Multigrind® Horizon software. New applications and updates<br />

are constantly being added to increase both productivity and<br />

precision. With the innovative Multigrind® Styx visualization<br />

software, grinding processes are optimized before production<br />

starts. At Haas Schleifmaschinen, software developers<br />

meet machine experts and customer experts meet an ambitious<br />

management team. This is what makes technology<br />

leaders work and creates the best conditions for a comprehensive<br />

range of solutions.<br />

“Check your ambitions,<br />

and don’t let the future slip away”<br />

All in one: the machine<br />

The Multigrind® Radical is an “all in one” machine, but not<br />

a universal grinding machine. It was explicitly developed<br />

for the future of tool grinding. According to Wember there<br />

are no limits to this. Maximum precision for both rotary<br />

and plate tools. This means that all customer requirements<br />

can be produced extremely flexibly on just one tool grinding<br />

machine in the future. Milling cutters, inserts and drills<br />

are ground via a chaotic loading system, as required. In large<br />

quantities or as very small series from batch size 1 to 1,000.<br />

On a small scale: very big<br />

The Multigrind® Radical bridges the gap between opposites:<br />

the new tool grinding machine is on the one hand maxi -<br />

mally equipped and yet radically reduced. It stands rocksolid<br />

on a minimal footprint and is ideally suited for a low<br />

hall height. The machine bed is inherently rigid and made<br />

38 no. 1, March <strong>2022</strong>

machining center<br />

All in one: cutters, inserts, drills – all on one tool grinding machine<br />

of mineral casting. This makes the new Multigrind® Radical<br />

a small solo and space artist. Or a super productive production<br />

cluster with very low space requirements. Large production<br />

volumes and mixed jobs can be handled simultaneously<br />

with several Multigrind® Radicals extremely quickly and<br />

efficiently.<br />

Radical: faster<br />

According to Dirk Wember, the Multigrind® Radical is radically<br />

fast and very efficient. Best times for both tool change<br />

and wheel change have been announced. The parallel tool<br />

and grinding wheel change saves additional time. Apart from<br />

this non-productive times are consistently reduced. The announced<br />

increase in productivity will set new standards.<br />

And! the new Schnell will be very easy to handle.<br />

Mission: control<br />

A new innovative operating concept is also set to provide a<br />

surprise. Haas Schleifmaschinen is talking here about decoupling<br />

operation from the machine. According to Haas<br />

Schleifmaschinen, the machine operator is mobile and always<br />

up to date everywhere. Fully automated, unmanned series<br />

production becomes the production standard with the Multigrind®<br />

Radical. Haas is also going its own way with its operating<br />

concept and here, too, two opposites are combined:<br />

freedom and maximum control.<br />

Simply: get started<br />

The software developers have done a great job. The very fast<br />

integration into the production succeeds without much<br />

programming effort. Production starts immediately and<br />

without loss of time. Haas Schleifmaschinen promises no<br />

lengthy training during setup and operation. Programming<br />

is simple and makes very fast production changes possible.<br />

What’s more, Haas precision is uncompromising. With<br />

the Multigrind® Radical, there is no compromise on value,<br />

quality and precision. “This is our brand essence, we make<br />

no compromises here.” emphasizes Dirk Wember.<br />

Simply: the new fast<br />

“Simplify your work” with Multigrind® Horizon software, the<br />

Multigrind Radical is immediately ready for production. Parameterization,<br />

templates and ERP information form the data<br />

basis. No control is necessary. Just provide parts and start.<br />

Cloudgrinding<br />

“Cloudgrinding” is another buzzword behind which real<br />

added value is hidden. The machine control is located in the<br />

customer’s corporate network, the added value comes from<br />

the cloud. Additional performance service, current updates,<br />

physical information, safety instructions, process parameters<br />

can be easily retrieved from the cloud on request. So all<br />

additional information is available without time delay. Secure,<br />

certified and pay per use. In other words, only when the<br />

added value is actually needed. The Multigrind® Radical will<br />

definitely be a topic at the leading trade fair GrindTec.<br />

GrindTec <strong>2022</strong>, hall 7, booth 7014<br />

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

no. 1, March <strong>2022</strong><br />


machining center<br />

The latest grinding machine development<br />

with an innovative machine concept<br />

WALTER is introducing its<br />

latest addition to the machine<br />

range portfolio at the exhibition<br />

GrindingHub <strong>2022</strong> in<br />

Stuttgart, Germany from May<br />

17-20 th in hall 9 stand A50:<br />

The HELITRONIC G 200<br />

tool grinder with innovative<br />

machine concept on a small<br />

footprint.<br />

On a floor space of less than 2,3 m 3<br />

the cost-efficient HELITRONIC<br />

G 200 offers tool grinding at its<br />

best: production and re-sharpening<br />

of rotationally symmetrical<br />

tools in the diameter range<br />

of 1 to 125 mm, with a maximum<br />

tool length of 235 mm and a<br />

The Top loader offers automation without increasing the foot print of the machine<br />

tool weight up to 12 kg. Maximum grinding wheel<br />

diameter is 150 mm.<br />

The ergonomic design and the integrated and<br />

swivelling multifunction touch panel with a 21.5”<br />

monitor facilitates the operation and accessibility<br />

of the working area. A low-vibration solid mineral<br />

cast bed and the C-frame construction offers high<br />

damping capabilities and temperature stability<br />

resulting in maximum precision in grinding. The<br />

linear axes X, Y, Z are built according to the high<br />

WALTER quality standard. The rotating A- and<br />

C-axes are equipped with torque motors and provide<br />

an unprecedented lifetime with minimum<br />

service effort. For maximum flexibility, a loading<br />

system is available: The “top loader” is directly<br />

integrated into the working envelope of the machine<br />

for easy access and therefore requires no additional<br />

space. Suitable for tools from diameter 3 mm<br />

to 16 mm, the maximum tool capacity of the loading<br />

system is for example 500 tools at a diameter of<br />

3 mm. The top loader uses WALTER-standard robot<br />

pallets and automated electrical teaching.<br />

The HELITRONIC G 200 uses the worldwide pro -<br />

ven grinding software HELITRONIC TOOL STUDIO<br />

from WALTER, which provides ease of programming<br />

with the greatest possible flexibility.<br />

HELITRONIC G 200 from WALTER: new innovative<br />

tool grinding machine concept on a small footprint<br />

further information: www.walter-machines.de<br />

40 no. 1, March <strong>2022</strong>

Top productivity for large workpieces<br />

machining center<br />

work with a pallet size of 800 x 800 mm with<br />

axis travel of 1,400 x 1,200 x 1,350 mm and a<br />

load capacity of up to 3,000 kg. Extremely durable,<br />

powerful spindles ensure particularly<br />

high machine availability.<br />

Increased productivity thanks to<br />

uninterrupted operation<br />

The MA-8000H can be equipped with more<br />

additional pneumatic and hydraulic connections<br />

through the pallets making optimum<br />

use of specific requirements for unmanned operation.<br />

For example, this enables automated<br />

loading and unloading processes during<br />

machining time. The machine has also been<br />

designed so that even a very large volume<br />

of chips can be reliably removed – ensuring<br />

maximum machine capacity utilisation. The<br />

“sludge less tank” option developed in-house<br />

also prevents accumulations of small chip<br />

residues in the coolant tank, significantly<br />

reducing the effort required for its cleaning.<br />

The integrated Okuma OSP-P300MA control<br />

system also makes it very easy to operate<br />

and can be supplemented with various control<br />

technology applications at the customer’s request.<br />

Set-up and maintenance of the new machining<br />

center has also been significantly simplified<br />

by a particularly user-friendly machine<br />

design.<br />

The Okuma MA-8000H machining center<br />

By introducing the new horizontal MA-8000H machining<br />

center on the market Okuma is able to optimally meet corporate<br />

requirements for automated manufacturing solutions for large<br />

workpieces.<br />

The particularly high powered model in the MA-H series gives customers<br />

a number of advantages: the production capacity for large workpieces has<br />

been significantly increased and productivity improved thanks to increased<br />

automation options. In addition to that, energy consumption can automatically<br />

and sustainably be drastically reduced by using special features.<br />

The dimensions and performance capabilities of the new MA-8000H<br />

have been massively increased compared to the previous model so that its<br />

handling of very large and heavy workpieces is even better: the machine can<br />

Reduced environmental impact<br />

with maximum precision<br />

It is becoming increasingly important to companies<br />

to significantly reduce their CO 2<br />

emissions,<br />

especially in the field of semiconductor<br />

production, renewable energies or when manu -<br />

facturing e-vehicles. Okuma meets this requirement<br />

perfectly with the new MA-8000H<br />

thanks to various energy-saving features: the<br />

proven thermo-friendly concept guarantees<br />

highest dimensional stability and accuracy –<br />

even in long-term operation. The integrated<br />

“ECO suite plus” provides an innovative<br />

energy saving system which allows the user<br />

to monitor and adjust energy consumption<br />

and CO 2<br />

emissions in real-time. The machine<br />

automatically reduces its power consumption<br />

during idle times while maintaining stable<br />

accuracies. Delivery of the MA-8000H will<br />

start in Europe in July, with pre-orders being<br />

accepted now.<br />

further information: www.okuma.eu<br />

no. 1, March <strong>2022</strong><br />


components<br />

Medical technology<br />

More efficiency in the manufacture of<br />

cardiovascular products<br />

Since its foundation in 1970,<br />

Aerotech has developed into a reliedupon<br />

partner of the medical industry.<br />

Their medical business unit has long<br />

been one of the strongest in terms of<br />

innovation and turnover of motion<br />

con trol and positioning systems. The<br />

steadily growing portfolio includes<br />

laser welding and stent cutting solutions<br />

as well as purpose-built motion<br />

systems and components that can increase<br />

throug<strong>hp</strong>ut while maintaining<br />

maximum precision. Over the years,<br />

Aerotech has become one of the main<br />

suppliers of motion control systems for<br />

the manufacture of implantable interventional<br />

cardiovascular devices.<br />

“Aerotech’s commitment to quality and performance<br />

has always been a perfect fit for<br />

the needs and requirements of the medical<br />

industry. So it was natural for us to focus<br />

more on this industry,” says William Land,<br />

business development manager for Aerotech,<br />

Inc. and responsible for the medical device<br />

market segment. Even more than other industries,<br />

medical technology requires a<br />

deeper technical understanding of the applications<br />

and manufacturing requirements.<br />

“Working closely with partners and customers<br />

on an ongoing basis has given us the<br />

industry insight we need to provide valuable,<br />

future-proof automation solutions to<br />

medical OEMs for nearly 50 years,” he says.<br />

First and foremost, it is a matter of understanding<br />

the needs and developments of the<br />

market. Another important task is to keep<br />

up to date and closely observe which medical<br />

technology developments the industry is<br />

focusing on.<br />

“We must always be pushing our capability<br />

developments to realise the desired<br />

medical technologies of the future,”<br />

William Land continues.<br />

William Land,<br />

business development manager<br />

at Aerotech, Inc.:<br />

“Working closely with partners<br />

and customers on an ongoing<br />

basis gives us exactly the industry<br />

insights we need to provide<br />

valuable and future-proof<br />

automation solutions to medical<br />

OEMs for nearly 50 years”<br />

Integration and automation partner Aerotech was involved in the development of some of the first lathes for cutting intraocular<br />

lenses and has been supplying specialist products to the interventional cardiovascular industry since the early 1970s. As a result,<br />

Aerotech has world-renowned tube laser machining systems that are relied upon by the largest medical OEMs and device<br />

manufacturers in the world. “We are able to manufacture fully integrated machines for custom applications,” asserts<br />

William Land, business development manager at Aerotech, Inc.<br />

42 no. 1, March <strong>2022</strong>

components<br />

Precise laser processing at maximum speed<br />

In the field of interventional cardiovascular device manufacturing,<br />

Aerotech is one of the main suppliers of motion control<br />

systems and has been for many years. “We manufacture<br />

custom-built linear and compact rotary servo systems<br />

that are critical to the manufacture of stents and many other<br />

trans-catheter devices and their delivery systems,” explains<br />

William Land. “Our mature technology enables precise laser<br />

processing of catheters and stents at speeds that make them<br />

economical for the market.”<br />

Fewer machines for the same number of stents<br />

For example, the fully-integrated VascuLathe motion system<br />

combines automated material handling functions with direct-drive<br />

linear and rotary motion. “Because of the throug<strong>hp</strong>ut<br />

a truly integrated design offers, medical device manufacturers<br />

need fewer machines to produce the same number<br />

of stents compared to conventional production methods,”<br />

William Land says of the benefits. However, due to its flexibility,<br />

the VascuLathe can also be used, for example, to meet<br />

an increased and varying production demand on the existing<br />

production area.<br />

Precise microlaser processing is particularly in demand<br />

in medical technology; the AGV3D laser scanner is<br />

optimally designed for this, but is also used<br />

in additive processes<br />

Innovations for the entire industry<br />

“As experienced developers and automation partners, we can<br />

keep pace with the very short innovation cycles in the industry,”<br />

emphasises Simon Smith, European director at Aerotech.<br />

“This future-oriented, constructive cooperation at eye level is<br />

very much appreciated by our customers.” The stent manufacturing<br />

solution is also merely a continuation of the successful<br />

high-performance motion systems and components<br />

for medical technology and life science applications.<br />

Other examples from the medical technology solution<br />

range include stent, guidewire, and catheter cutting, pacemaker<br />

and catheter laser welding systems, intraocular lens<br />

(IOL) and contact lens manufacturing, DNA and blood sequencing,<br />

X-ray machines, MRI scanners and CAT scanners.<br />

VascuLathe: innovative cutting system for<br />

precise stent production at high throug<strong>hp</strong>ut<br />

Automated material handling<br />

As a complete motion and material handling subsystem, Vascu -<br />

Lathe includes an automated, pneumatically-activated ER collet<br />

assembly and an optional combined bushing/tube feed mechanism.<br />

This enables the sequential, fully automated produc -<br />

tion of various products from tube material of any length.<br />

Also a wet cutting configuration is available for applications<br />

that require cooling fluid during the cutting process.<br />

Advanced control architecture<br />

As a platform, the VascuLathe is available with a powerful,<br />

yet simple and intuitive Aerotech controller. Users can optimise<br />

current, speed and position servo loops for maximum<br />

performance without much programming. Additional functions<br />

such as multi-block lookahead minimise geometry<br />

errors even at the smallest radii by “anticipating” tracking<br />

errors. With the “position synchronized output” (PSO) function,<br />

laser pulses can be controlled synchronously in order<br />

to maintain optimal laser power coupling at variable cutting<br />

speeds.<br />

Customer-focused integration<br />

One of Aerotech’s focuses is to provide exactly as much integration<br />

as the customer needs. “Many medical OEMs have<br />

in-house automation and machine-build groups or preferred<br />

integration partners,” specifies William Land. “Aerotech is<br />

considered the first point of contact and subject matter experts<br />

for precision motion control subsystem integration for<br />

these teams.”<br />

In other cases, medical OEMs were looking for a partner<br />

to help them manufacture the entire manufacturing cell for<br />

a specific process. “We are able to produce fully integrated<br />

machines and manufacturing systems for individual application<br />

areas,” assures William Land. “In every case, we ensure<br />

that the systems we have in operation at our customers’ facilities,<br />

whether individual components or complete machines,<br />

operate at full capacity and deliver high-quality results.”<br />

And Simon Smith emphasises in conclusion: “Manufacturers<br />

of cardiovascular products gain a competitive advantage<br />

in the highly competitive market of medical device<br />

manufacturing with our high-precision motion systems<br />

and components. We will be happy to advise interested<br />

parties in detail. We would also be pleased to welcome you<br />

on our new homepage.<br />

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

no. 1, March <strong>2022</strong><br />


components<br />

We don’t have to be there to be there<br />

In these times of local and national lockdowns<br />

due to Covid-19, the manufacturing<br />

sector has continued to support the economy<br />

by continuing to work in safe and<br />

managed environments. However, in these<br />

times, the requirement for technical support<br />

to maximise cutting tool performance<br />

remains a priority. With travel restrictions<br />

and lockdowns this could prove difficult to<br />

deliver, but with its new LiveTechPro app<br />

CERATIZIT is providing the platform for<br />

its technical sales and applications engineers<br />

to have their eyes and ears there with<br />

you when you need them.<br />

The innovative “LiveTechPro” solution from<br />

CERATIZIT provides immediate and competent<br />

visual support to deliver technical assistance in<br />

case of machining issues or simply to help optimise<br />

processes. It features a live, bidirectional<br />

video and audio connection between the customer’s<br />

machine operator/production engineer<br />

and the technical support team from Ceratizit.<br />

This ensures a reliable service that can be activated<br />

within seconds to ensure production continues<br />

to run smoothly. “Whilst our success has<br />

been built on the direct technical support our<br />

engineers give our customers on site and we<br />

would always want to work this way as a first<br />

choice, we are operating in extraordinary times<br />

and facing new challenges on a daily basis and<br />

ongoing support for our customers remains our<br />

main priority,” says Tony Pennington, managing<br />

director, Ceratizit UK & Ireland. “The LiveTech-<br />

Pro app is the next best thing to a physical<br />

visit, allowing our team to provide that support<br />

remotely and ensuring that customers continue<br />

to benefit from the performance advantages of<br />

our latest <strong>tooling</strong> developments.”<br />

The technology involved with LiveTechPro will<br />

enable detailed discussions to take place as if a<br />

Ceratizit engineer was on-site, specific issues or<br />

elements of a component can be highlighted on<br />

screen, downloaded if necessary, for detailed<br />

discussion with responses and solutions being<br />

provided there and then in terms of technical<br />

advice. The LiveTechPro system allows for multiple<br />

levels of operation via smartphone or tablet,<br />

with conventional video being the starting point.<br />

However, it is also compatible with virtual reality<br />

technology to take support to the next level,<br />

with virtual hands-on support. “It is the next best<br />

thing to actually standing next to a machine, it<br />

Ceratizit’s LiveTechPro allows operators and engineers to get live access<br />

to cutting tool issues deep within the machine tool<br />

With LiveTechPro Ceratizit’s technical support is always by your side<br />

will be our eyes and ears during these times of lockdown and reduced<br />

personal interaction as and when we cannot physically make a visit, as<br />

the interface between customer and Ceratizit employee using LiveTech-<br />

Pro is seamless and provides the reassurance that our technical sales and<br />

applications engineers don’t have to be there, to be there for them.”<br />

The LiveTechPro app is available for iPhone and Android operating<br />

systems and can be downloaded directly from Ceratizit website or the<br />

appropriate App Store.<br />

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

44 no. 1, March <strong>2022</strong>

components<br />

Live tool speed increaser realizes 9X tool cost savings<br />

in less than a year<br />

Kurt Machining (Minneapolis, Minnesota) specializes<br />

in providing precision CNC machined parts, using<br />

state-of-the-art technologies and up to 5-axis machining.<br />

Since 1952, this 110,000 ft. 2 shop has provided its<br />

customers in a variety of high-quality demand markets<br />

with components and welded assemblies. These include<br />

aerospace, defense, semiconductor, energy, automotive<br />

and more. A very flexible shop, Kurt produces<br />

parts ranging from micron-sized semiconductor components<br />

to 2000 lb. workpieces for the defense sector.<br />

On a recent project, where 5,000 pieces of 6,060 aluminum<br />

were to be engraved on a Hwacheon horizontal turning<br />

center, Kurt engineering manager, Shawn Eisenshank, had<br />

concerns over the cycle times. He turned to his local <strong>tooling</strong><br />

distributor, Abrasive Specialists, Inc. (ASI) and their <strong>tooling</strong><br />

partner, Platinum Tooling, for suggestions. Leigh Kinnan of<br />

ASI worked with the local Platinum Tooling representative,<br />

Cody Papenfus, to test run a Heimatec speed increaser, with<br />

the goal of increasing RPM on the machine and decrease<br />

part cycle time, with a documentation of the potential savings.<br />

After performing the calculations in consultation with<br />

Preben Hansen, president of Platinum Tooling and exclusive<br />

importer for Heimatec products in North America, it was<br />

determined a significant savings could be realized.<br />

As Shawn Eisenshank notes, “This is one of those classic<br />

scenarios, where the theoretical has proven out in practice,<br />

as we’ve seen exactly the results ASI and Platinum Tooling<br />

proposed in their test calculations.”<br />

Cody Papenfus of Hexis in Plymouth, Minnesota, who is<br />

the area rep for Platinum Tooling adds, “We say we put our<br />

expertise to work at the spindle of the machine and, in this<br />

case, that’s exactly what happened. The speed increaser performed<br />

as expected, the customer got the results promised<br />

and it was a win-win, for all. We serve our customers for the<br />

long haul and successes like this one are the big reason.”<br />

Detailing the application, ASI demonstrated that a 1:3<br />

speeder increased the spindle RPM enough that when coupled<br />

with the nearly 3X increase in the feed rate on the machine,<br />

would produce a significant improvement to the current<br />

machining cycle. Calculating the reduction in machining<br />

cost per part and factoring the cost of the speed increaser,<br />

it was determined the use of the Heimatec product onboard<br />

the Hwacheon turning center would result in a 9X cost saving<br />

for the customer, in the first year’s production run on this engraved<br />

aluminum component.<br />

Kurt Machining performs both vertical and horizontal<br />

milling and turning, complex assemblies and weldments, delivering<br />

with rapid lead times. CAD compatibility is offered<br />

for web-based communications and fully interactive manufacturing<br />

engagement for its customers. The company performs<br />

contract manufacturing in high quantity as well as<br />

prototyping for new designs. Kurt also performs impact extrusion,<br />

heat treating and cleanroom operations including<br />

ultrasonic cleaning of stainless steel and aluminum components<br />

and assemblies, with cleaning to Class 1000 with 100<br />

protocol. The company is ISO 9001:2015 and AS9100D plus<br />

NADCAP certified. Kurt Machining is quality certified by<br />

the U.S. Government to MIL-Q-9858 and MIL-I-45208.<br />

further information: www.platinum<strong>tooling</strong>.com<br />

no. 1, March <strong>2022</strong><br />


components<br />

New CNC software simplifies usage of<br />

latest five-axis machine tools<br />

Available now, the latest version of Flexium software<br />

from CNC specialist NUM includes an enhanced<br />

RTCP (Rotation Tool Center Point) function with tool<br />

vector programming that significantly simplifies the<br />

usage of five-axis machine tools.<br />

As one of the original developers of RTCP, NUM continually<br />

enhances the function to meet the changing needs of machine<br />

builders and end-users. The company’s implementation<br />

of RTCP includes twenty-four predefined kinematic configurations<br />

and its Flexium+ CNC systems can accommodate different<br />

kinematics on the same machine, for example, when<br />

different milling heads are needed.<br />

NUM’s basic RTCP function, invoked by ISO code G151,<br />

offers a number of user-specified variants. The function can<br />

be activated with an inclined coordinate system or after a positioning<br />

move. In either case, the CNC system automatically<br />

calculates the mechanical offset to ensure that the tool center<br />

point is always in touch with the defined workpiece surface<br />

The RTCP function in<br />

NUM’s Flexium CNC<br />

software can now be<br />

activated by the actual<br />

positions of the rotary axes<br />

The tool vector programming option of NUM’s RTCP<br />

function enables the direction of the tool to be determined<br />

by the vectors’ components along the X-, Y- and Z-axes,<br />

rendering the part program independent of the machine<br />

kinematics.<br />

In some circumstances, aligning the workpiece to be<br />

processed on the machine can be a complex procedure. In<br />

these cases, to increase productivity, instead of moving the<br />

workpiece, NUM’s Flexium+ CNC system can now compensate<br />

for positioning deviations (including angles) by applying<br />

appropriate correction values. The workpiece remains misaligned,<br />

but the CNC system is aware of the deviations and<br />

compensates for them automatically.<br />

NUM’s Flexium software, version<br /> or higher, now features<br />

a special HMI (Human-Machine<br />

Interface) to allow the corresponding<br />

correction values to be<br />

entered. The coordinate system resulting<br />

from the shifts and rotations<br />

is called a Balanced Coordinate<br />

System (or BCS) and the compensation<br />

function is known as 3DWPC<br />

(3D workpiece compensation).<br />

NUM’s Flexium CNC software now includes an enhanced RTCP function with<br />

3D workpiece compensation that significantly simplifies the programming of<br />

five-axis machine tools<br />

Also the software now includes a<br />

function to help machine users accelerate<br />

the roughing operation’s<br />

tunings and then achieve optimal<br />

surface finishes. Invoked by ISO<br />

code G732, the new function simplifies<br />

parameter optimisation and<br />

automatically computes pre-settings<br />

for roughing and finishing with<br />

adjustable smoothing levels.<br />

while the rotary axes are moving. The RTCP function can<br />

also be activated by the actual positions of the rotary axes.<br />

Until now, programming 5-axis machines has often been<br />

considered an onerous task. The rotary axes are usually programmed<br />

directly with their angular position, which has<br />

the advantage that the position of the machining head can<br />

be imagined when viewing the part program. The disadvantage<br />

is that the part program depends on the kinematics of<br />

the machine, and cannot be transferred to another 5-axis<br />

machine without modification.<br />

To help machine operators achieve optimal results, NUM<br />

has introduced a new algorithm that keeps the pivot point at<br />

constant speed. Part programs generated by CAD/CAM systems<br />

invariably comprise a multitude of small G01 segments –<br />

in the case of rotary axes, these are often distributed inhomogeneously<br />

– resulting in speed variations which affect surface<br />

quality. The new algorithms maintain constant speed at<br />

pivot points during the movement of rotary axes, smoothing<br />

the discon tinuities, resulting in an improved surface.<br />

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

46 no. 1, March <strong>2022</strong>

components<br />

New lubricant for mask production<br />

The manufacturer of ultrasonic welding equipment<br />

for mask production, among other things, wanted more<br />

process reliability in the machining of materials that are<br />

difficult to machine: with tools from Paul Horn GmbH<br />

and cooling lubricants from Zeller+Gmelin, the Karlsbad-based<br />

specialist for ultrasonic components and<br />

systems was able to find two suitable partners at once.<br />

Ultrasonic welding from<br />

Weber Ultrasonics is used for<br />

the production of medical masks<br />

The ultrasonic<br />

sys tems are used,<br />

for example, in<br />

the production of<br />

a wide variety of<br />

medical technology<br />

applications,-<br />

for example medical<br />

masks or components<br />

such as<br />

membranes,<br />

adapters, connectors<br />

and even sur -<br />

gical instruments.<br />

In particular, the<br />

demand for ultrasonic<br />

welding technology<br />

for the series<br />

production of<br />

medical masks<br />

made of non-woven<br />

fabric has increased<br />

dramatically<br />

due to the<br />

pandemic. The ver -<br />

tical range of<br />

manufacture at<br />

Weber Ultrasonics<br />

is enormous: almost all components and assemblies of the<br />

ultrasonic systems are manufactured in-house. For a special<br />

titanium component, the so-called converter, the machining<br />

process used is grooving, or more precisely axial grooving. In<br />

order to be able to guarantee process reliability and long tool<br />

life even with increasing quantities, new tool solutions were<br />

sought. Previously, chatter marks on the surface of the deep<br />

grooves were a recurring problem.<br />

Zubora ensures more process reliability<br />

With a new axial grooving system from the Tübingen tool<br />

specialist Horn, a process-safe solution was found: the new<br />

S15A grooving insert had produced a stable machining process<br />

right away. At the same time, a new cooling lubricant<br />

is used in the form of Zubora TTS, which was developed<br />

in a joint project between Horn, Zeller+Gmelin and a major<br />

machine manufacturer. “All the experience of the lubricant<br />

manufacturer, machine builder and tool specialist has<br />

gone into the development of the new lubricant,” says Jürgen<br />

Schmid, product and project manager sales at Horn, seeing<br />

By using the newly developed cooling lubricant Zubora TTS<br />

in combination with the axial grooving system from Paul Horn,<br />

swirl chips are now optimally broken during the machining<br />

of pure titanium TiAI6V4 and ensure a safe process<br />

an enormous advantage. “The idea of the project was to develop<br />

a new and more efficient coolant for the machining of<br />

superalloys. Zeller+Gmelin has achieved this with the development<br />

of the new coolant.” And business unit manager<br />

Thorsten Wechmann from Zeller+Gmelin adds: “After<br />

successful tests on various superalloys, the first field test at<br />

Weber Ultrasonics was now on the agenda. By using Zubora<br />

TTS in combination with a new tool coating, the tool life<br />

could be significantly increased. The completely new formulation<br />

leads not only to an increase in tool life but also to an<br />

improvement in the surface quality of the component. Furthermore,<br />

it was possible to increase the cutting parameters<br />

and thus sustainably increase profitability.”<br />

Chip breaking under control<br />

Weber Ultrasonics says that by optimally matching the tool<br />

and the cooling lubricant, it has been possible to significantly<br />

improve chip control. As a result, 50 of the titanium components<br />

can now be produced off the shelf in an unmanned<br />

shift, so to speak, and the problem of uncontrolled long chips<br />

is now a thing of the past. Tool wear has also improved measurably<br />

and visibly thanks to the new Zubora coolant.<br />

The new cooling lubricant Zubora TTS is a fully synthetic<br />

solution. According to manufacturer Zeller+Gmelin, the<br />

focus of the novel concept was on lubrication, chip breakage<br />

support and surface quality improvement. “We have developed<br />

the new coolant for the productive machining of titanium<br />

and other super alloys. However, the product can be<br />

used multifunctionally and also brings advantages when<br />

machining a variety of other materials,” explains Thorsten<br />

Wechmann.<br />

further information: www.zeller-gmelin.de<br />

no. 1, March <strong>2022</strong><br />


components<br />

A sensible addition to<br />

mechanical clamping elements<br />

ENEMAC, the clamping specialist offers now the<br />

new series ESG clamping nut, which perfectly complements<br />

the established types ESB and ESD.<br />

The clamping force is strengthened by a special crowngear<br />

transmission with a rectangular deflection of the<br />

rotation and lateral manual operation. Thanks to the<br />

newly designed power transmission elements, ESG<br />

achieves significantly lower height and overall compact<br />

dimensions compared to the ESB and ESD types, which<br />

allows its use in extremely cramped conditions.<br />

By turning a small nut, which is attached to the side of<br />

the housing, the internal gear is driven with a minimum<br />

force effort and the counterpart is tightened.<br />

The principle is simple, the effect very large, because<br />

this concept allows a clamping force of 12 t to be manually<br />

applied by each worker. Thread sizes from M16 to<br />

M30 are available. The power clamping nut is screwed<br />

onto the existing bolt, then tightened through the lateral<br />

hexagonal bolt to the specified torque using a commercially<br />

available torque wrench. The clamping nut secures<br />

your workpiece or tool safely and quickly. The series<br />

ESG has been designed for workpieces and tools with a<br />

varying component size since the screw depth is not restricted<br />

due to the continuous thread.<br />

For harsh environment applications there are special<br />

variants such as high temperature versions up to 673 K.<br />

Optionally available is a version with additional disc<br />

spring package for compensation of the clamping upstroke,<br />

which is recommended when clamping heavy<br />

compactor dies for the higher operation safety.<br />

The ENEMAC power clamping nuts can be used at<br />

any time, whether by the original equipment manufacturer<br />

or as a retrofitting element.<br />

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

Measuring high-precision master workpieces<br />

Precision requirements for workpieces are becoming<br />

more demanding and are often in the micrometer<br />

range. This means that requirements for master workpieces<br />

for gaging benches and machines as used in the<br />

automotive industry are also increasing. The Video-<br />

Check® V HA, like all Werth machines, is traceable and<br />

can be used to calibrate the calibration masters at the<br />

factory.<br />

If the quality management system requires a DAkkS certificate,<br />

the machine can be calibrated by Werth’s own DAkkS<br />

lab in accordance with DIN EN ISO/IEC 17025. Werth<br />

is the first and only manufacturer to provide DAkkS calibration<br />

certificates for optical, and tactile, and computed tomography<br />

coordinate measuring machines. DAkkS (Deutsche<br />

Akkreditierungsstelle) is the national accreditation body of the<br />

Federal Republic of Germany. It is legally mandated to carry<br />

out accreditations of conformity assessment bodies.<br />

With its solid granite construction, special air-bearing<br />

technology, and thermally stable scale system, the Video-<br />

Check® V HA achieves measurement uncertainty in the range<br />

of tenths of microns. The high-precision machine has an<br />

integrated vertical rotary<br />

axis to prevent heavy<br />

workpieces such as shafts<br />

and tools from sagging<br />

under their own weight.<br />

In addition to external<br />

dimensions, the flexible<br />

3D machine can also measure<br />

a number of other<br />

features, such as teeth,<br />

transverse holes, etc. The<br />

VideoCheck® V HA is also<br />

available for workpieces<br />

up to 1000 mm in length<br />

and 320 mm in dia meter.<br />

The combination of image<br />

processing and the SP80<br />

tactile sensor allow for the<br />

very highest measurement<br />

precision.<br />

VideoCheck® V HA – higher<br />

precision with a larger<br />

measurement range<br />

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

48 no. 1, March <strong>2022</strong>

components<br />

Clear conditions for tool grinding<br />

The KFA 1500 Compact Filter System is a high-performance, low-maintenance ultra-fine<br />

filter system for grinding high-speed steels (HSS) and carbide materials, which promises<br />

optimum quality with high cleanliness of NAS 7/8 or 3-5 µm even for very large batches<br />

The larger the tool grinding batches and the more<br />

grinding machines are involved in the filtration process,<br />

the more necessary are high-performance largescale<br />

and special filter systems for cleaning contaminated<br />

grinding oils. With the KFA 1500 Compact Filter<br />

System, the machine manufacturer Vomat from<br />

Treuen (Germany) provides tool manufacturers and<br />

regrinders with a high-performance, low-maintenance<br />

ultra-fine filtration system for grinding high-speed<br />

steels (HSS) and carbide materials, which promises optimum<br />

quality with high purity of NAS 7/8 or 3-5 µm<br />

even for very large batches.<br />

Demanding grinding applications require a high-performance<br />

filter system that positively supports and influences<br />

the process flow. Ultra-fine filtration allows grinding oils to<br />

remain in the system significantly longer. Cleanly filtered,<br />

they help to increase the dimensional accuracy and surface<br />

quality of the products. Additionally, the right filter system<br />

also reduces energy consumption and disposal costs.<br />

Vomat’s product portfolio includes solutions for stand-alone<br />

systems, modular systems, central systems and individual<br />

customized specialty systems with central and decentralized<br />

functions. One example is the KFA 1500, a special ultrafine<br />

filtration system that promises tool manufacturers and<br />

regrin ders optimum economic quality even for large batches<br />

of different materials. The KFA 1500 (260” x 100” x 103” h) has<br />

a tank volume of 10,000 liters and a filter capacity of 1,500<br />

liters/minute. The medium is filtered by high-efficiency<br />

precoat filters in full flow at a filter fineness of 3-5 μm. Filtration<br />

takes place on demand and in an energy-efficient<br />

manner via a frequency-controlled system pump. The special<br />

drying unit is optimally designed for large batch sizes.<br />

The cooling performance in the cold water circuit of the<br />

KFA 1500 is 200 kW in continuous operation. The temperature<br />

accuracy in the tolerance range of up to +/- 0.2 ° C contributes<br />

to the optimum quality of the product.<br />

Due to the precoat principle, there is no contamination of<br />

the swarf by filter aids. The residual moisture of the swarf is<br />

between 5 and 10 % and the recyclable material is processed<br />

directly into a suitable transport container for recycling companies.<br />

The control technology can also be monitored and<br />

operated remotely. Also VOMAT offers a compression cooler<br />

with external condenser and high control accuracy, as well as<br />

a material-dependent pre-separation system.<br />

GrindTec <strong>2022</strong>, hall 3, booth 3027<br />

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

no. 1, March <strong>2022</strong><br />


fairs in alphabetical order<br />

AMB Stuttgart, Germany<br />

(September 13-17, <strong>2022</strong>)<br />

CCMT Shanghai, China<br />

(April 11-15, <strong>2022</strong>)<br />

EMO Hanover, Germany<br />

(September 18-23, 2023)<br />

EPHJ Geneva, Switzerland<br />

(June 14-17, <strong>2022</strong>)<br />

FABTECH Toronto, Canada<br />

(June 14-16, <strong>2022</strong>)<br />

FEIMEC São Paulo, Brazil<br />

(May 3-7, <strong>2022</strong>)<br />

FILTECH Cologne, Germany<br />

(March 8-10, <strong>2022</strong>)<br />

GrindingHub Stuttgart, Germany<br />

(May 17-20, <strong>2022</strong>)<br />

GrindTec Augsburg, Germany<br />

(March 15-18, <strong>2022</strong>)<br />

Hannover fair Hanover, Germany<br />

(May 30 to June 2, <strong>2022</strong>)<br />

IMT Brno, Czech Republic<br />

(October 4-7, <strong>2022</strong>)<br />

IMTS Chicago, USA<br />

(September 12-17, <strong>2022</strong>)<br />

intertool Wels, Austria<br />

(May 10-13, <strong>2022</strong>)<br />

JIMTOF Tokyo, Japan<br />

(November 8-13, <strong>2022</strong>)<br />

METALEX Bangkok, Thailand<br />

(November 16-19, <strong>2022</strong>)<br />

METAV Düsseldorf, Germany<br />

(June 21-24, <strong>2022</strong>)<br />

SIMTOS Seoul, South Korea<br />

(May 23-27, <strong>2022</strong>)<br />

sps Nuremberg, Germany<br />

sps on air digital (November 8-10, <strong>2022</strong>)<br />

Stone+tec Nuremberg, Germany<br />

(June 22-25, <strong>2022</strong>)<br />

Surface Stuttgart, Germany<br />

Technology (June 21-23, <strong>2022</strong>)<br />

TIMTOS x TMTS Taipei, Taiwan<br />

(February 21-26, <strong>2022</strong>)<br />

current status<br />

<strong>2022</strong><br />

<strong>2022</strong><br />

2023<br />

<strong>2022</strong><br />

<strong>2022</strong><br />

<strong>2022</strong><br />

<strong>2022</strong><br />

<strong>2022</strong><br />

<strong>2022</strong><br />

<strong>2022</strong><br />

<strong>2022</strong><br />

<strong>2022</strong><br />

<strong>2022</strong><br />

<strong>2022</strong><br />

<strong>2022</strong><br />

<strong>2022</strong><br />

real &<br />

digital exibition<br />

<strong>2022</strong><br />

<strong>2022</strong><br />

<strong>2022</strong><br />

<strong>2022</strong><br />

<strong>2022</strong> real &<br />

digital exibition<br />

TIMTOS x TMTS Taipei, Taiwan<br />

(February 21-26, <strong>2022</strong>)<br />

<strong>2022</strong> real &<br />

digital exibition<br />

trade fair dates as by beginning of February <strong>2022</strong>; we are not responsible for reliability of these dates<br />

50 no. 1, March <strong>2022</strong>

impressum<br />

ISSN 2628-5444<br />

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copyright © <strong>2022</strong> Dr. Harnisch Publications<br />

editorial<br />

Aerotech, Inc. ...................... 42<br />

BMR elektrischer und elektronischer<br />

Gerätebau GmbH ..................34<br />

Boehlerit GmbH & Co. KG ............17<br />

CemeCon AG .......................12<br />

CERATIZIT Deutschland GmbH .. 18, 44<br />

CHIRON Group .....................25<br />

EMAG Group ...................... 24<br />

ENEMAC Gesellschaft für Energie- und<br />

Maschinentechnik mbh ............ 48<br />

Gleason Corporation .................22<br />

GrindingHub .......................25<br />

GrindTec <strong>2022</strong> ......................21<br />

Hartmetall-Werkzeugfabrik<br />

Paul Horn GmbH ..................13<br />

Haas Schleifmaschinen ...............38<br />

IFR International Federation<br />

of Robotics ....................... 20<br />

KAPP GmbH & Co. KG ..............30<br />


FABRIK GMBH & CO. KG. .........19<br />

advertising index<br />

company finder<br />

Lach Diamant<br />

Jakob Lach GmbH & Co. KG ..........6<br />

Leitz GmbH & Co KG ................10<br />

Liebherr-Verzahntechnik GmbH ......35<br />

MAPAL Fabrik für<br />

Präzisionswerkzeuge Dr. Kress KG ...11<br />

MAG IAS GmbH ....................26<br />

NUM AG .......................... 46<br />

OKUMA Deutschland Gmbh .........41<br />

PLATIT AG .........................14<br />

Platinum Tooling ....................45<br />

TORNOS SA ........................36<br />


PER PRODURRE. .............. 22, 24<br />

UNITED GRINDING Group .........23<br />

Vomat GmbH .......................49<br />

Walter Maschinbau GmbH .......... 40<br />

Werth Messtechnik GmbH. . . . . . . . . . . 48<br />

Zeller+Gmelin GmbH & Co. KG .......47<br />

Aerotech GmbH ........................................................page 11<br />

Boehlerit GmbH & Co. KG ...............................................page 3<br />

CERATIZIT Deutschland GmbH .........................................page 5<br />

Günther Effgen GmbH ..................................................page 13<br />

JIMMORE International Corp. ...........................................page 19<br />

KAPP GmbH & Co. KG .................................................page 21<br />

Lach Diamant Jakob Lach GmbH & Co. KG .............................front cover<br />

PLATIT AG ...................................................inside front cover<br />

Reishauer AG ....................................................... back cover<br />

VDW – GrindingHub ...................................................page 17<br />

no. 1, March <strong>2022</strong><br />


Eyed Industry 4.0<br />


Reishauer‘s ARGUS process and component monitoring provides unprecedented insight into grinding<br />

and dressing processes and the condition of critical machine components. Process Monitoring<br />

and optimize with data analysis, identify necessary maintenance work in advance, plan<br />

efficiently and reduce downtime to a minimum - ARGUS makes it possible:<br />

• Grinding and dressing process monitoring<br />

• Collision monitoring<br />

• Monitoring of machine components<br />

• Web-based process view<br />

• Data analysis<br />

• Process optimization<br />

• Potential zero-defect production<br />

Reishauer AG, Switzerland | reishauer.com

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