hpt 2022 #3

ISSN 2628-5444
high precision tooling
Machine Tools, PCD, PVD, CVD, CBN, Hard Metal 2022 – 3
■ Seeing mobility change as an opportunity ■ Stable trend towards automation in the metal cutting industry ■
■ Tradition. Passion. Innovation: How it all began ■ Automated disassembly of battery systems ■

Tradition. Passion.Innovation.
For more information visit
www.lach-diamant.de
office@lach-diamant.de
100 years of innovation since 1922
AMB Stuttgart - Hall 3 · Stand D12
®

ISSN 2628-5444
editorial
Adding highlights…
Eric Schäfer
editor-in-chief
…was reserved for the old
masters of the fine arts in earlier
times, who gave their paintings
a dab-like light effect with a
brushstroke. In their own way
the heroes of our cover story
are also artists who worked
brilliantly together. And just as
in art the interplay of highlights,
reflections and shadows results
in a realistic-looking painting, the collaboration between the
right tool with a perfect cutting edge, an excellent machine
and experienced specialists results in perfect surface finishes
with a mirror finish. Machining centers and precision
tools will also get their glamorous appearances at AMB,
International Exhibition for Metalworking in Stuttgart.
First product announcements can already be found in
this issue of hp tooling.
The trend towards automation in the machining industry
continues and now extends through the entire production
chain. To achieve this all links in the chain must be
interlinked. The article on page 48 shows what an
efficient automation concept for machining
operations can look like.
Speaking of efficiency. The recycling of battery systems
will play an important role for sustainable electromobility
in the future, but requires a high degree of automation
in the dismantling process for ecological efficiency.
Authors Thomas Götz and Andreas Gebhardt from the
Fraunhofer Institute for Manufacturing Engineering
and Automation IPA describe how industrial disassembly
of battery modules and e-motors can be carried out.
Eric Schäfer
editor-in-chief
high precision tooling
Machine Tools, PCD, PVD, CVD, CBN, Hard Metal 2022 – 3
Come and see for yourself:
www.harnisch.com
■ Seeing mobility change as an opportunity ■ Stable trend towards automation in the metal cutting industry ■
■ Tradition. Passion. Innovation: How it a l began ■ Automated disassembly of battery systems ■
Perfectly positioned.
The international specialist magazines from Dr. Harnisch Publications
You can now explore our newly designed website, with a
clear focus on responsive design and easily usable applications.
Alongside the free-to-use digital magazine editions, you will
find bonus news coverage, events, subscription and
general information on all our magazines. Take a look at
www.harnisch.com for all relevant content.
Our publications include:
- Technology & Marketing -
no. 3, August 2022
3

table of contents
cover story
High quality diamonds for a brilliant result
Dazzling teamwork between SIT, Horn and Mazak 6
materials & tools
Solid PCD endmills – a new opportunity for increased productivity for those ready to strike 10
The right tool for high-quality tapping 12
Flexible changing system reduces inventory and changeover time significantly 14
Double feed with the same axial force 16
Successful shift work 17
LACH DIAMANT looks back on 100 years – 13 th part
Forty years of spark erosion for efficient PCD machining – utilizing sparks over grinding 18
processes
High precision HSC machining in mold making for medical technology 26
Seeing mobility change as an opportunity 28
machining center
Welcome to the Machine. Farewell to the past… 30
Como Industries quintuples pin gauge output with the TSCHUDIN CUBE 350 33
Planetary lapping machine for PCD and CVD 34
The new productive STUDER machine S36 35
Big cost savings into aerospace production 36
Highest precision with two options 37
components
Automated disassembly of battery systems
Thomas Götz and Andreas Gebhardt, IPA 38
Analyzing and optimizing cleaning processes 44
Reliable cable guiding on industrial robots 47
Efficient automation with robotics, software and storage system 48
news & facts 19
fairs 24, 50
impressum & company finder 51
4 no. 3, August 2022

ARGUS-Eyed Focus on
the Grinding Process
Reishauer‘s ARGUS process and component monitoring offers
insight into the grinding and dressing process previously thought
impossible. Among others, ARGUS monitors grinding processes,
optimizes them with data analysis, recognizes maintance issues
in advance, reduces down-time to a minimum:
• Grinding and dressing monitoring
• Collision monitoring
• Monitoring of machine components
• Web-based process overview
• Data analysis
• Process optimization
• Potential zero-defect manufacturing
Come and visit us at the
Hall 5/Booth B51
Reishauer AG | info@reishauer.com | reishauer.com

cover story
High quality diamonds for a brilliant result
Dazzling teamwork between SIT, Horn and Mazak
(source: Horn/Sauermann)
“We branched out into the sectors that others had
avoided”, says company founder Walter Schumacher.
Together with his son, Stefan, he runs the company
Walter Schumacher Impuls Technik GmbH, (SIT).
The company specialises in the development and production
of special valves and stand-alone valve so lutions,
which are used in numerous industries.
The product range includes valves for all types of media,
ranging from high-vacuum valves to high-pressure valves
rated up to 800 bar. One of these special solutions made from
aluminium consists of several helium valves, various sensors,
pressure relief valves and throttles, which control and
regulate various pressures. The emphasis is on the surface
quality of the mating surfaces, which ensures functionality
in high-technology analysis. SIT achieves a surface quality
of Ra 0.012 µm (4.724409e-7") using a diamond tool from
Paul Horn GmbH and by having invested in a new turning/
milling center from the machine manufacturer Mazak.
“Our surface finish specification at the start of the project
was Ra 0.02 µm (7.87402e-7")”, says Stefan Schumacher.
The surface quality of the valve block plays a crucial role, as it
acts as a sealing surface in the valve assemblies. “Sealing hydraulic
valves with oil pressures of around 450 bar is technically
relatively simple to implement. With valves for controlling
the flow of helium or other gases, that have to tolerate
pressures of up to 800 bar, this is technically a very difficult
challenge, which not many people want to take on”, explains
Walter Schumacher. Even with technical perfection, it is not
possible to produce a perfect sealing surface. The leakage
value is 1 x 10-7. For this reason, the almost perfect, brilliantfinish
surface of the valve block plays a key role.
Complete valve block machining
Before making the move, SIT relied on a specially developed
polishing process to produce the valve block after machining.
However, the time and personnel required for reworking
meant that optimisation was required. SIT lacked the
right machinery for this, however. After moving to the newly
built company headquarters, investments in a new turning/
milling center made it to the planning stage, but the machine
manufacturer was yet to be selected. “We approached a few potential
suppliers with our requirements. Mazak immediately
expressed a high level of interest and proposed a complete
valve block machining solution”, says Stefan Schumacher.
6 no. 3, August 2022

cover story
A successful cooperation since 20 years:
Stefan Schumacher (SIT) talks to Paul Hauser and
product manager Jürgen Schmid (both at Horn)
(source: Horn/Sauermann)
The solid workholding attachment developed by Mazak
(source: Horn/Sauermann)
The company opted for the INTEGREX i-200ST turning/
milling center. The INTEGREX is designed for rigidity and
stability, added to which the spindle runs smoothly and with
low vibration. In addition to the machinery, Mazak and another
partner designed a workholding attachment for the
300 mm (11.811") long, 110 mm (4.331") wide and 30 mm
(1.181") high valve block. The attachment is mounted directly
on the spindle flange, where the chuck is normally. The number
of clampings was consequently reduced from nine to two.
SIT: the company
Almost 40 years of experience in top-quality valve
technology has enabled Walter Schumacher to build up
a solid customer base in almost every industry sector.
The main field of activity is the manufacture of special
valves and customised, stand-alone solutions.
Development, production and distribution are all under
one roof. SIT offers its customers short lead times from
initial contact to the finished product, resulting in
lower costs and direct contact with decision-makers.
The use of modern machinery and specially trained
personnel enables the company to produce large
series as well as one-offs with consistent quality and
in accordance with individual customer requirements.
Each and every valve undergoes quality control. The
workmanship, performance and leak tightness –
up to and including a helium leak test with a report
if required – are carefully checked before the goods
are dispatched. Tested assemblies, including components
such as flow regulators, filters, pressure relief valves
and pressure transmitters, in addition to the valves,
reach SIT customers as a complete package.
Horn takes the top spot
Once the machine concept had been decided, the next step
was the tool planning. “After initial contact was made and the
machining task had been outlined, it quickly became clear
to me that the finishing processing should be performed using
our DTM milling system”, says Horn product manager
Jürgen Schmid. The tool is tipped with a monocrystalline
diamond (MCD) cutting edge. The second cutting edge is
tipped with PCD and is used as a pre-cutter to achieve the
defined allowance of 0.02 mm (0.001") for the MCD. “As well
as Horn, an alternative tool manufacturer was also in the
running. However, Horn solved the task on the first attempt,
while the other manufacturer needed three attempts. This
made our choice clear, not only because we were immediately
satisfied with the result, but also because of how impressed
we were by the company’s expertise. We also use other tool
systems from Tübingen and are very satisfied with them”,
says Walter Schumacher.
The surface milled by the Horn DTM tool system achieved
a measured value of Ra 0.012 µm (4.724409e-7"). The tool
body has a diameter of 125 mm (4.921") and has two cutting
edges – an MCD insert and a PCD pre-cutting insert
mounted opposite each other in the milling cutter body.
The six free seats are fitted with carbide balancing inserts.
The tool is finely balanced at Horn to ensure it runs without
vibration. The insert seats in the DTM body can be adjusted
in the axial direction via an adjusting screw. Every ten-degree
rotation moves the insert seat by 0.01 mm (0.0004"). This
means that the axial run-out of the individual cutting edges
can be adjusted with micron precision. The internal coolant
supply ensures targeted cooling of the contact zone and enables
efficient chip removal. The low mass of the aluminium
body protects the spindle and reduces energy consumption
compared with steel bodies.
no. 3, August 2022
7

cover story
Delicate surfaces
“One difficulty was the large number
of holes drilled into the surface
to be machined. Necessarily, brilliant-finish
milling must be the final
machining operation, as otherwise
very fine chips from drilling, reaming
and thread milling would damage
the reflective mirror surface”,
explains Schmid. “Even fingerprints
can render the sealing surface
unusable later on”, adds Stefan
Schumacher. The interrupted cut
across the drilled holes posed no
problem for the Horn tool. During
processing, the milling cutter moves
once longitudinally over the workpiece
at a speed n = 5,000 rpm and
with a feed rate of v f = 500 mm/min
(19.685"/min). The cutting speed is
v c = 1,960 m/min (6430.446 ft/min).
To reduce re-cutting of the chips,
the tool is set at a minimum lead angle
of 0.008 degree. A commercially
available emulsion is used for the
coolant.
“We are very satisfied with the
performance of the tool. In series
production, we now achieve
surface qualities between Ra 0.012
(4.724409e-7") and Ra 0.014 µm
(5.511811e-7")”, summarises Stefan
Schumacher.
Craftsmanship
To produce surfaces with a mirror
finish, the quality of the tool cutting
edge plays a decisive role. The quality
of the cutting edge is reflected
in the surface to be machined. The
final grinding and polishing of the
MCD cutting edge requires craftsmanship.
Similarly to when cutting
a diamond for jewelery, the finish
grinding of a tool cutting edge for
high-gloss machining is done by
hand. Air-bearing grinding tables
with a top made of solid granite
provide optimal conditions for
grind ing the cutting edges. A micros
cope with 200 x magnification
is used for optical inspection. Un
der this magnification, the cutting
edge must be absolutely free from
imperfections. For grinding MCD
ball nose end mills for high-gloss
machining of freeform surfaces,
Horn developed a grinding machine
that can be used to reliably grind
diameters down to 0.2 mm.
The Horn DTM milling system with MCD cutting edges made
surface qualities down to Ra 0.012 µm (4.724409e-7") possible
(source: Horn/Sauermann)
Polishing the MKD blades is like a craft
(source: Horn/Sauermann)
SIT has been relying on solutions from the tool manufacturer since about 20 years.
“The cooperation for the production of the valve block has once again shown us
why we have Horn as a tool partner. Their know-how impresses us. We would also
like to emphasise the joint cooperation with Mazak engineers. Everyone involved
worked hand in hand and gave everything to solve this difficult machining task,”
says Walter Schumacher.
further information: www.phorn.de
8 no. 3, August 2022

Eagles do not take flying
lessons from pigeons.
↓
The new Multigrind® Radical:
The predator among the grinding machines.
Haas Schleifmaschinen GmbH
www.multigrind.com

materials & tools
Solid PCD endmills – a new opportunity for
increased productivity for those ready to strike
Example of solid PCD tipped
ball endmill and drill
made on EDGe
Example of solid PCD tipped
ball endmill and drill
made on EDGe
The EDGe is capable of making
solid PCD tipped drills under 1 mm
Used in the right application, a diamond (or
PCD – polycrystalline diamond) cutting tool
can last up to 20 times that of an equivalent carbide
tool. The exciting news is, a new generation
of solid PCD helical endmills and drills made
on ANCA’s EDGe machine is set to further extend
this advantage. There is strong demand
emerging in the 3C (electronics) and aerospace
manufacturing industries for such tools that can
deliver improved productivity and quality in the
finished workpiece.
As a 5-axis CNC machine, the ANCA EDGe with its
rotary EDGe process, is ideally suited to create complex
3D cutting tool forms. ANCA has a heritage
of software development that supports design and
manu facture of complex geometries on rotary cutting
tools using ToolRoom software. In addition to helical
drill points, our latest software release allows customers
to manufacture helical endmill (square, corner radius
and ballnose) forms.
A conventional brazed PCD cutter has a shear cutting edge
that limits cutting performance
10 no. 3, August 2022

materials & tools
This capability is coming at just the right time for PCD cutting tool
manufacturers, as there is an alignment of market and technology developments
making solid tipped PCD tools economical and desirable.
Users of PCD tools are asking for longer life and better cutting performance
than is possible with a shear cutting edge on a tradi tional
PCD tool. The aerospace and 3C industries in particular, are driving
this. Additionally, the solid PCD tip production processes have matured,
and with that, have become more affordable.
Flexibility sets PCD tipped tools apart
Solid PCD tipped tools offer a number of advantages. Most important
is the complete flexibility in tool geometry. The EDGe machine’s Tool-
Room software allows users to create helical cutting tools, both drills
and endmills, with far superior cutting properties compared to equivalent
tools with brazed planar PCD inserts.
Traditional PCD rotary cutting tools feature flat PCD tips brazed onto
a carbide tool body. While the PCD will extend the life of the cutting
edge, by design the cutting geometry is a shear (straight) edge with a flat
hook face. This geometry inherently limits the performance of the tool.
With solid PCD tipped tools, tool designers can have greater flexibility
to create unique geometries specific to various cutting applications, in
the same way as is done for conventional carbide tools. This applies not
only to the cutting profile, but importantly to flute and gash geometry
which are critical to chip formation and evacuation.
Another important consideration is that while the smallest tool diam
eter for brazed PCD tools is typically 6 mm, solid PCD tipped tools
can readily be made much smaller than this. Micro tools (drills and
endmills) are gaining widespread use in the 3C market with the EDGe
capable of producing drills down to 0.3 mm and milling cutters under
3 mm. Finally, unlike coated carbide tools, these new drills and endmills
can be resharpened many times readily, effectively extending the tool’s
usable life.
ANCA’s EDGe machine has the capabilities to produce these unique
tools. Of all forms of PCD machining processes, rotary erosion, that is
used by the EDGe, is by far best suited to producing solid PCD tipped
drills and endmills. Wire erosion cannot create flute or gash forms, and
laser ablation has highly expensive upfront cost and is ultimately uneconomical
on anything but the very smallest of solid tools.
ANCA’s EDGe has both electrical discharge machining and carbide
grinding capability. This is an important consideration given these solid
PCD tipped tools will naturally require the flute and OD form to extend
into the carbide. With both electrical discharge machining and grinding
capability, one has the choice to select the optimal process for dif -
ferent material removal.
Built on a heritage of solid carbide grinding capability, ANCA Tool-
Room software is renowned for its inherent flexibility and ease of use.
ANCA EDGe is a highly versatile machine that performs equally
well in other applications such as conventional brazed PCD shear tools
and solid carbide grinding. The EDGe machine, with its latest software
capable of producing helical endmills and drills, will reward cutting
tool manufacturers who are quick to pounce on a market that is always
demanding new tools with better price to productivity performance.
further information: www.anca.com

materials & tools
The right tool for high-quality tapping
The Japanese company Yamawa is a world leader
in threading tools manufacturing with four highly
specialized factories all located in Japan that guarantee
the production of 1,400,000 taps per month. The
Z-PRO VU series of taps by Yamawa is especially designed
for use with water-soluble cutting fluid and represents
the optimum solution for tapping on high performance
machining centers. Recently the company
has broadened the range of VU series with new products
and sizes.
With continuous innovations,the company aims to provide
the market with the best threading solutions, from aerospace
and automotive industries to ship building, machine
tools, electric appliance, IT and many other fields. Among
Yamawa’s offer, the Z-PRO series represents the state of the
art of high performance tapping; developed to guarantee
high performance and reliable tapping, as well as extending
tool life significantly thanks to exceptional chip evacuation.
VU series, especially designed for
multifunction machining centers
The VU series, part of the Z-PRO, is a machine tap series
designed to be used in modern multifunction machining centers
and for tapping with either oil or water soluble cutting
fluids, aiming at ensuring the highest quality and flexibility.
VU taps are suitable for the machining of a broad range of
materials, from steel to stainless steel and nonferrous materials,
the tapping speed goes from 10 to 30 m/min, depending
on the application. Taps are made of coated premium powder
high-speed steel (HSSP) based on Yamawa specifications
that ensure excellent wear resistance; the coating is suitable
for water-soluble oil applications and ensures that the tools
have superior heat resistance and longer life than conventional
machine taps. Another strength of Z-PRO VU series is
the special geometry: Yamawa has completely revised the design
of flute shape to target it on medium tap ping speeds; this
allows efficient chip ejection resulting in a lower and more
stable tapping torque and, consequently, longer tool life with
both the use of emulsion and oil.
Part of the VU series are spiral fluted taps for blind holes
(VUSP) and spiral pointed taps for through holes (VUPO),
tools able to deliver top performances, reliability, and quality
in every manufacturing context, from mass production to
small-batch applications.
To show the flexibility and durability of VU taps, a comparative
test ran at 15 m/min cutting speed on a machining center
with rigid holder (synchronized feed). In this application,
two different materials were machined in the same task: C45
and A5052. Lubricant was water-soluble oil and the tap was
the coated spiral fluted Yamawa Z-PRO VUSP M6x1 (tapped
hole diameter of 5 mm, depth 5~12 mm). After tapping 1600
holes in the two materials, the tap was still running while the
competitor’s tap broke after only 480 holes: Yamawa tap has a
longer tool life by 42 %.
The special design and
coating of the VU series
are also efficient in preventing
chipping: in a test
on a M10x1.5 tap machining
C50 at 20 m/min the
wear after tapping more
than 1100 holes shows,
while with a conventional
tap chipping occurs
after 900 holes.
Optimized shape
flute for improved
thread surface finish
Another interesting technical
feature is the optimized
shape of the flute
Taps of Yamawa
Z-Pro VU series
in the chamfer portion of VUPO taps that improves the chip
ejection significantly. When tapping into a through hole on
a machining center, chips often hit the clamping device;
they can cause severe problems such as edge chipping and
oversized threads that lead to poor quality threads. Field
test carried on using VUPO taps with emulsion for tapping
AISI304 steel at 10 m/min demonstrated how the improved
edge sharpness and discharge of chips of Yamawa taps clearly
results to enhanced thread surface finish.
Thanks to its technical innovations Z-PRO, the VU series
of taps has been recognized as a benchmark for high performance
tapping across Europe. Yamawa has recently
broadened the range with new sizes. The VUSP for blind
holes comprises taps up to M24 size for both the M and MF
thread types, while the range of VUPO for trough holes goes
from actual M3~M16 to M2~M24 sizes (from M16 both
the M and MF thread types are available). The VUPO and
VUSP taps are available in stock, also with the long shank
(JIS standard).
The new VUSP CH coated spiral fluted tap with axial
lubrication hole for the use with water-soluble coolant has
also joined the VU series. In these taps the coolant hole
diameter is optimized to allow abundant internal lubrication
for drastic heating and welding reduction resulting in improvement
of the wear resistance and the quality of the internal
thread. VUSP CH taps discharge chips smoothly, guaranteeing
continuous machining and process reliability.
The new VUSP E(1.5P) completes the range. The chamfer
length is 1.5 pitches, making the tool ideal for machining
blind holes where there is little room between the bored
hole depth and the full thread length. Thanks to the unique
flute shape, this type of taps has improved chip ejection and
reduced cutting resistance that allow longer life and excellent
internal threads quality.
further information: www.yamawa.com
12 no. 3, August 2022

Cubic boron nitride for tough cases
materials & tools
Paul Horn GmbH is expanding its tool portfolio
for machining hard materials and other steels. Tools
tipped with cubic boron nitride (CBN) offer optimised
machining of nickel-based and other superalloys as
well as powder metallurgical and hardened steels. The
ultra-hard cutting material CBN demonstrates its
strengths in smooth cutting and interrupted cutting
when hard turning and grooving.
By including extensions in the standard range for the
Supermini 105, Mini 11P, 229 and 315 systems, Horn offers
the user fast delivery of the desired tool systems from stock.
The Supermini system is available in left and right hand
versions with different corner radii. The CBN-tipped variants
are suitable for internal machining from a diameter of
2 mm (0.079"). Different projection lengths of the solid carbide
bodies are also available. Tools in the Mini family can
be used from an internal diameter of 6.8 mm (0.268") and
are also available in left and right hand versions. The single-edged
tool type 315 is suitable for external grooving operations
from a groove width of 0.5 mm (0.012"). In the cutting
insert system 229 the previous CBN substrate CB 50 is
replaced by the higher-performance substrate CB 35. The
cutting inserts are available with two different corner radii
and cutting widths from 3 mm (0.118") to 6 mm (0.236").
Horn is expanding its tool portfolio with CBN-tipped tools for
machining hard materials
After diamond, CBN is the second-hardest material known
to man. Tools made from CBN wear much slower than
other cutting materials when used properly. This makes it
possible to achieve higher dimensional and shape accuracy
and also means that hard materials (steel up to 70 HRC)
can be machined reliably. There are no different types of
CBN. The difference is the CBN volume fraction, the fillers,
the grain size and the ceramic/metallic binder phase (cobalt/
nickel), resulting in different CBN substrates. Hard machining
with CBN cutting materials is usually done without coolant
because the cutting material has a high heat resistance
and the high temperature within the chip formation zone has
a positive effect. An insufficient supply of coolant or interruptions
in cutting lead to high, thermally induced stresses
in the structure of the indexable insert, causing cracks in
the structure and possibly even destroying the indexable insert.
During hard machining most of the heat generated in
the shear zone is dissipated via the chip. While carbide suffers
a significant loss of hardness at about 800 °C (1,472 °F),
the hardness of CBN remains almost unchanged, even at
temperatures up to 1,200 °C (2,192 °F). Another significant
advantage is chemical resistance, particularly at the prevailing
temperatures.
AMB 2022, hall 1, booth J10
further information: www.phorn.de
Perspective Change:
3D-lasered
multi-tooth tools
for high-speed and high-quality
machining of hard materials
Visit us:
www.zecha.de
13.-17.09.2022
Stuttgart
Hall 1 · Stand A47

materials & tools
Top performers for turning hardened
steels and aluminium
It was a quantum leap in the development of machining
technology worldwide when General Electric
first offered polycrystalline diamond cutting edges in
1973, followed 1975 by CBN boron nitride cutting edges
for machining non-ferrous metals – primarily aluminium
– and hardened steels.
With passion, innovation and success, LACH DIAMANT has
been involved since almost fifty years in its now 100-year history.
Many patents bear witness to this until today.
In a special show at AMB in Stuttgart, LACH DIAMANT
will present the favourite products that have become a “must”
in mass production:
→ PCD chip breaker for the process-safe turning of
aluminium the PCD cutting insert with active
chipbreaker (international patents) «IC-plus» world’s best
PCD
chipbreaker
«IC-plus»
world’s best for
process-safe
turning of
aluminium
→ CBN inserts for the finish turning of high-alloy hardened
steels and grey cast iron «CBN-DUO-power»
(tipped with two CBN cutting edges)
AMB 2022, hall 3, booth D12
further information: www.lach-diamant.de
Flexible changing system reduces inventory and
changeover time significantly
Heimatec, a world leader in live tools, angle heads
and multi-spindle drill heads, announced immediate
availability of its popular u-tec® flexible changing
system on all live tools in the company’s product line.
Tools are now available for the most popular machine
tool models in the market, according to Platinum Tooling
Technologies, Inc. president, Preben Hansen. Platinum
Tooling is the exclusive North American importer. The
company plans to include its u-tec® flexible changing system
on all live tools and angle heads, going forward, according
to Hansen. He notes this design offers the benefits of quick
change, while maintaining exceptional rigidity.
The u-tec® patented changing system allows a standard ER
output live tool to accept various adapters for different applications.
This allows users the ability to have quick changeover
of tools on almost any lathe or mill, using a single tool, without
having to commit to a quick-change system on the initial
purchase. A facemill adapter, for example, can be quickly
positioned into the standard holder, without the need for a
new tool purchase. This significantly reduces inventory costs
as well as changeover time for the busy shop.
The u-tec® system, according to Preben Hansen, “…represents
a real improvement in lathe live tooling design. u-tec®
allows great user flexibility and ensures a solid connection
due to the polygon design built into both the tool and
The typical
live tool adapter
hardware of the u-tec® system
the adapter. This polygon connection helps guarantee the
proper position and alignment of the adapter inside the tool.
Once the insert is properly positioned and the collet nut
is clamped, the cutting tool will have excellent rigidity and
torque transmission.” He further explains the unique collet
nuts on the u-tec® system have internal threading for clamping
stability and that this new tool adapter system enables the
actual cutting tool to be brought into closer proximity to the
bearing, thus further improving performance in use.
Every adapter in the u-tec® system is furnished complete
with the necessary clamping nut and holding wrench, they
are available in various outputs such as arbor, Weldon, ER
extension and blank styles. The u-tec® system is available for
all major turning machines on the market today. Heimatec
currently manufactures over 10,000 live tool types and has
a full inventory at Platinum Tooling, their North American
importer, headquartered in the Chicagoland area.
further information: www.platinumtooling.com
14 no. 3, August 2022

materials & tools
Supermini Set
Paul Horn GmbH offers users now its proven
Supermini tool holder system with face clamping as
a set, thereby responding to customer requests for
different tooling system heights.
The heart of
metal working
beats in Stuttgart!
The new Supermini set will be presented at AMB 2022 in
Stuttgart, hall 1, booth J10, for the first time.
Horn now offers users its proven Supermini
tool holder system with face clamping as a set
With this holder variant, clamping is not carried out via
the lateral surface of the cutting insert but via a clamping
wedge on the face. This results in a greater holding force
on the insert and thus high rigidity of the entire system.
Furthermore this style of clamping increases repeatability
when changing the insert and provides better utilisation of
the available space. This shows to be a great advantage on
Swiss-type lathes, as the user can change the cutting insert
without removing the tool holder.
GET
YOUR
TICKET
NOW!
The set consists of a round shank holder and three different
clamping elements. The latter are suitable for the three
different insert heights of the Supermini system, 03, 04 and
05. When ordering the desired diameter of the round shank
holder can be selected. Choice of the diameters is 10 mm,
12 mm, 16 mm, 20 mm, 22vmm, 25 mm and 28 mm. Inch
dimensions are available in 1/2", 5/8", 3/4" and 1" diameter.
All sets are available from stock.
AMB 2022, hall 1, booth J10
further information: www.phorn.de
amb-expo.de

materials & tools
Double feed with
the same axial force
EMUGE offers a new tool to reduce main machining
times: the EMUGE Punch Drill. This high-feed
drill is suitable for machining cast aluminium alloys
with at least 7 % Si content.
The possible drilling depth ranges up to approx. 4 x D, the
nominal diameter range from 4 mm to 8.5 mm. Machining is
carried out with a normal drilling cycle on CNC machines,
cutting speeds and coolant pressures are the same as for
conventional drilling.
An innovative chip breaker helps keeping the chip short
and controlling the machining forces. Newly developed surface
treatments and a hard coating specially designed for
this application enable reliable chip removal and increase
process reliability.
The most impressive feature is that the axial force is actually
halved when this high-feed tool is used with the feed
of the series tool. By increasing the feed at the same speed,
main times are reduced and machine capacities are economised.
The reduced power consumption of the machine is
also in support of sustainability.
The EMUGE Punch Drill helps to conserve resources
In short: the tool benefits from shorter machining times
and a high metal removal rate. Higher productivity and less
strain on resources are positive consequences. The tool life is
comparable to conventional drilling tools despite the higher
feed rate. The superior self-centering capability of the drill tip
enables the best possible positioning accuracy on the holes.
For multi-step-drilling operations, the EMUGE Punch Drill
is also available as a step tool.
further information: www.emuge.de
Innovation in the precision tools sector
At AMB ZECHA Hartmetall-Werkzeugfabrikation
GmbH will be demonstrating how to implement maximum
precision, outstanding quality both in the product
and during the production, and maximum productivity
in micro-machining. New developments and
expanded product ranges guarantee innovative tool
solutions.
Change your perspective:
3D lasered multi-tooth cutters –
MARLIN
Miniature tools, sophisticated tool contours and the machining
of ultra-hard materials can’t be combined? Think again!
Thanks to the latest technological processes and our highly
developed tool expertise, ZECHA is entering a new era with
brand new 3D lasered tools from the MARLIN family. These
specially developed multi-toothed tools, consisting of the
960, 962, 965 and 966 series with their geometrically defined
cutting edges, set the benchmark when machining extremely
hard materials. The combination of high efficiency, quality
and feed rate opens up a new world and makes diverse 3D
shapes and geometries possible for a wide range of applications
– including ultra-hard machining of glass.
IGUANA
In comparison to our competitors’ tools, ZECHA’s IGUANA
tools offer a 400-fold longer tool life in copper, a 15-fold
longer in fibre-reinforced PEEK and a 10-fold longer tool life
in lead-free brass because of their unique fusion of technologies.
Thanks to the innovative laser processing of the diamond
coating, its small diameter multi-cutters shine brightly
as a result of their extreme sharpness, extreme wear resistance,
very long service life and very high process reliability.
Thanks to various design options – spiraled, lasered on both
sides, with or without a cooling system – this tool family can
be used to machine a wide range of applications and the most
demanding materials with smooth surfaces and a performance
of the highest quality.
With the 935 series of the IGUANA family, ZECHA has
yet developed another high-end line. The torus or ball-nose
end mills with spiralling are equipped with a patented cutting
edge clearance (EP 2450427B1*), which is specially designed
for your needs when making moulds.
AMB 2022, hall 1, booth A47
further information: www.zecha.de
16 no. 3, August 2022

Successful shift work
materials & tools
Circular saw blades for aluminum composite panels and aluminum profiles
Aluminum composite panels place high demands
on cutting tools. LEUCO has developed special saw
blades with carbide and diamond cutting edges for
these materials. These ensure long tool life even for
demanding production processes. In addition, LEUCO
also offers highly productive and durable tools for
aluminum profiles.
Furthermore, as a manufacturer specializing in tools for
wood, plastics and non-ferrous metals, LEUCO has developed
a program for aluminum composite panels, because
these composite materials are becoming increasingly common
in sectors such as retail store and trade show construction,
as well as window and facade production.
Carbide cutting edges for demanding applications
Cutting and processing of aluminum composite panels are
not difficult when using appropriate tools. LEUCO recommends
selecting saw blades according to the number of
pieces produced and the type of panel. For single cuts of
common composite panels, saw blades with the flat trapezoidal
tooth shape (type “TRF-F-FA”) are the first choice.
LEUCO supplies the TRF-F-FA with cutting edges made
of HL Board 04 Plus carbide. This cutting material, first introduced
in 2017, is particularly resistant to fracture and impact.
Saw blades with this cutting material achieve the longest
edge lives that are currently possible at LEUCO for
tungsten-carbide products. For sawing non-ferrous metals,
HL Board 04 Plus is a good choice.
Saw blades with the TRF-F-FA tooth shape are suitable for
common machines, for example, from Holz-Her or Striebig,
as well as for table saws, for example, from Altendorf, also
without a scoring saw blade. This saw blade can be used
to process the usual composite panels with intermediate
layers of plastic. Such composite panels for construction
applications are usually between 2 mm and 6 mm thick, including
the two approximately 1 mm thick aluminum top
layers. The usual thickness of the panels is 4 mm. The middle
layer is usually made of polyethylene or polypropylene.
Diamond for mineral-filled layers
A special case is aluminum composite panels with mineral-filled
polymers, for example, the ALUCOBOND® and
ALPOLIC® brands. Due to the mineral fillings, these composite
panels achieve very high fire classifications. For such
panels LEUCO recommends saw blades with the HR tooth
shape and polycrystalline diamond cutting edges (DP).
They achieve surprisingly long service lives despite the hard
middle layers. Another important strength of the two tooth
shapes TRF-F-FA and HR are the almost burr-free cuts. This
is one of the most important quality criteria when evaluating
circular saw blades for non-ferrous metals.
Processing of aluminum composite panels in packs is
also extremely demanding. For this purpose, a combination
of DP cutting material and the TRF-F-FA tooth shape
has proven to be the best. This saw blade is sharp and robust
enough to cut several layers of aluminum composite panels
in one pass. At the same time, it achieves a tool life with
which this highly productive type of processing also makes
economic sense.
LEUCO has developed the HW TR-F-K saw blade
especially for aluminum profiles, for non-ferrous metals;
it can be used on chop saws, miter saws and table saws
Chop saw blades for aluminum profiles
Unlike panels, profiles are usually hollow sections. These are
also used in many industries. This includes window and trade
show construction – but also the machinery sector. There,
aluminum profiles serve as the basis for the construction of
fixtures and machine enclosures. In any case, before mounting
the profiles must be cut accurately, and, for example,
manufacturers of windows with aluminum frames usually
use miter cuts. For such work, LEUCO has developed
cross-cut and miter saw blades designed for light metals.
The newest development in this area is the HW TR-F-K saw
blade. It can be used on cross-cut and miter saws as well as
table saws. It is intended for cutting non-ferrous metals such
as aluminum, copper and magnesium. The HW TR-F-K is
specially designed for machines from Kaltenbach, Elumatec,
Emmeggi, RAPID and Eisele as well as for companies that
process such profiles in large numbers. This gives them a tool
that produces the best quality with exceptionally long tool
life. Wall thicknesses of profiles can be up to 5 mm. The saw
blade achieves its highest productivity with thicknesses of
2 to 3 mm. The HW TR-F-K is available with diameters from
350 to 600 mm.
further information: www.leuco.com
no. 3, August 2022
17

materials & tools
LACH DIAMANT looks back on 100 years – 13 th part
Poly – poly – or what?
Forty years of spark erosion for efficient
PCD machining – utilizing sparks over grinding
Horst Lach, managing director and CEO of
LACH DIAMANT, agreed to write an ongoing series
of articles about the development of diamond and CBN
tools and grinding wheels in modern industries.
Horst Lach is known as a true industry veteran, and
we are excited to have this pioneer of technology share
some insights from his over 62 years of professional experience
in the diamond tool business. This time our
focus is on “using sparks instead of grinding”.
In 1978 Horst Lach had a truly sparkling idea. Initially, it
led to efficient machining and forming of polycrystalline diamonds.
Thanks to this revolutionary invention it was possible
to implement new technologies, based on newly created
diamond tools. For example the machining of wood and plastics
in the furniture and kitchen cabinet industry, as well as
laminate and parquet flooring, circuit board, automobile and
automotive accessories industries and in many other areas.
Controlled impact
Up to 1978 it was traditionally thought, that only diamonds
could be used for machining diamonds. The discovery of
spark erosion and of the so-called EDG grinding method
(rotation procedure – electrical discharge grinding) by Horst
Lach, ignited a new, until then unimaginable, and much
wider distribution and use of PCD – a material introduced to
the market in 1973.
Horst Lach had a sparkling idea
Horst Lach utilized a mere 0.5 % of traceable cobalt present
in this polycrystalline compact material which otherwise
consists of 99.5 % pure diamond (during diamond synthesis,
single diamond grains with a size of 0 to for example 35 µ
are compressed under high pressure and heat and thus stimulated
to grow). Under the controlled impact from electric
sparks, single diamond grains are stimulated to break free
from the grip of the electrically conductive cobalt.
Pioneering PCD tools
LACH DIAMANT, having its 100 th anniversary, since Horst
Lach’s father, Jakob Lach, founded the company, did not only
use electric sparks for the development of pioneering PCD
tools. In order to create an efficient, precise procedure for
forming functional cutting edges on tools, the electric spark
had to be integrated with the diamond blade or the tool-moving
axes and edge controlers, respectively.
This was the beginning of LACH DIAMANT as a machine
ma nufacturer. Today, in 2022, automatic LACH DIAMANT
grinding machines for the production and sharpening of polycrystalline
diamond tools can be found all over the world.
A new generation of superior automatic LACH DIAMANT
grinding machines – capable of using graphite and/or copper
as the respective ideal rotation electrode – are now part of
the LACH DIAMANT machine programme.
Example: grinding of diamond saw blades
with a programme for multi-production
Individual presentations available
At GrindingHub in Stuttgart it was possible to see all innovations
and extras of the LACH DIAMANT EDG-plus-sparksharpening-machines
at the tradeshow – e.g. the «Dia-2200-
mini» and the special «contour-profiled» model for superior
profiling of metal-bond diamond and CBN grinding wheels.
For this reason, LACH DIAMANT invites all interested diamond
grinding companies to an individual presentation at
our grinding center in Hanau.
Horst Lach
further information: www.lach-diamant.de
18 no. 3, August 2022

Gleason Corporation announces the passing of
James S. Gleason, former chairman and CEO
news & facts
It is with great sadness that we announce the pass ing of
James S. Gleason, a Gleason board member and former
chair man and CEO of the company, who died on
June 17 th at the age of 88.
Being a great grandson of the company’s founder William
Gleason he contributed to the company in various roles, continuing
to serve as a director on the board up until his death.
1959 he started working in the company, holding various
positions to become CEO in 1981 (until 2002), and during
that time the company went through significant transformations,
more than doubling in size both through organic
growth and acquisition. The company then recommitted to
its strategy of global leadership in gear technology, broadening
its range of products and further expanding its geo -
graphic manufacturing footprint. In 2000 the company also
returned to private ownership (from a publicly traded company
on the NYSE).
Beyond his accomplishments in the company he held leadership
positions in industry trade organizations along with
board representation in various business, social, charitable,
and educational organizations.
further information: www.gleason.com
Change in the management
of the LMT Tools Group
Mr. Roland Benter took over the role of the CFO of the
LMT Tools Group as of August 1, 2022. He succeeds
Mr. Jochen Ohler who will leave the company on
December 31, 2022, by best mutual agreement.
Mr. Roland Benter will succeed Mr. Jochen Ohler in the role
of the CFO of the LMT Tools Group as of August 1, 2022.
Mr. Benter has extensive experience from senior financial
positions as well as commercial leadership roles including
managing director and consultant with mid-sized industrial
and automotive suppliers. He worked for several years in
the USA and India, has extensive knowledge in the management
of company transactions and a high level of competence
in process management to decisively advance the further
development of LMT Tools
from a financial, commercial
and legal point of view.
His motivating and congenial
manner set him apart.
Jochen Ohler was manag -
ing director and CFO since
June 2018. He has con tribut -
ed significantly to shap ing
the successful business of
the LMT Tools Group.
further information:
www.lmt-tools.com
Roland Benter
took over the role of the
CFO of the LMT Tools Group
as of August 1, 2022
Ex-Kuka executive Till Reuter joins forces
with NEURA Robotics
Since the start of automatica 2022, NEURA Robotics
has been shaking up the industry with a multitude of
world premieres. Now the Swabians are announcing a
small sensation that is likely to cause a stir way beyond
the automation scene. Till Reuter, former CEO of Kuka
and most recently chairman of the supervisory board
at the Müller Group, has literally let himself get carried
away by the doer attitude of the robotics pioneers into
a future that has already begun at NEURA Robotics.
So NEURA founder and CEO David Reger once again proves
that he leaves nothing to chance on his way to becoming the
man at the helm of a leading company. No one would have
believed that Reuter would ever add another robotics chapter
to his vita after the mega success with Kuka – so this alliance
means a great deal in the automation scene.
Now the experienced business leader is backing David
Reger, 20 years younger, with all his know-how and an impressive
global network – another indication of the potential
the cognitive robotics “Mady by Neura” holds. In record timing
Reger’s team has succeeded in closing major innovative
gaps in robotics and has laid the foundation for the everyday
use of robots alongside humans.
With the goal of revolutionizing the world of robotics,
David Reger won over approximately 20 specialists and an
investor for NEURA Robotics back in 2019. After just three
years, the Metzingen-based company presented the world’s
first robot that – thanks to cognitive abilities and humanlike
senses such as seeing, hearing and feeling – is able to act
and learn independently – in almost any environment.
further information: www.neura-robotics.com
no. 3, August 2022
19

news & facts
LACH DIAMANT – 100 Years
Tradition. Passion. Innovation
part 1: How it all began …
“When I held my first diamond in my hand in 1908, I
would not have imagined that one day diamonds would
not only be used in the automobile industry but also
for the machining of wood and plastics”. Jakob Lach,
the company founder, said this on camera in 1980.
It would become the preface for the first presentation
of a new technique for machining wood and plastics
– using diamonds as cutting material – the Dia
Tool. This video, with audio translated into multiple
languages, has lost none of its relevance for the choice
of appropriate tools within the furniture, flooring and
plastic industries, it can be viewed at:
https://bit.ly/LACHDIAMANT
In the 1980’s this video might have reached an interested
audience of millions of viewers at the international wood and
plastic trade shows, for example in Hanover, Milan, Atlanta,
Los Angeles and even in Beijing.
Despite his advanced age my father, Jakob Lach, was very
interested in all of the new, revolutionary technologies available
for diamonds, even though they were “only synthetic”
like the polycrystalline diamond. Jakob Lach was fourteen
years old the first time he held a diamond in his hands as a
young diamond grinder apprentice.
Diamond cutting as a trade
Born in Rückingen/today Erlensee, Jakob was the oldest of
four brothers and one sister. The parents operated a small
farm.
Company founder Jakob Lach
(photo taken in 1980)
In 1908 diamond cutting in Germany, to be exact, the cutting
of natural diamonds (brilliants), had become an official
trade in the last twenty years, with its center in Hanau
on the Main and along the river Kinzig. The pioneer who initiated
the cutting of diamonds in Hanau was Friedrich Houy.
January 1874 he achieved a breakthrough with a self-constructed,
water-propelled casting disc. He had succeeded
and could now cut diamonds, and he even shared his
newly gained know-how. Word spread quickly in parts of
Palatinate, in Idar-Oberstein, in the Odenwald area, the
Kinzig valley, in Hanau of course, and all the way from
Antwerp to Amsterdam.
People came to Mr. Houy in Hanau to learn, and later started
their own small cutting businesses. Hanau became the
center of diamond cutting. Until the beginning of World
War I several thousands of diamond cutters were employed in
Hanau and the surrounding areas.
A perfect decision
Young Jakob Lach must have had a good master during his
apprenticeship at Heckman, because from now on his life was
focused on diamonds, with all its facets. This became apparent
after the first world war. After serving in the Carpathians
during the war and being wounded, he was – like so many
others – without a job after the war. Nobody was interested in
manufacturing diamond jewellery at that time; he did a twoyear
apprenticeship as a merchant.
Apprentice training as diamond polishers back then –
exemplary and unique for diamond shops at that time
A business registration from December 1919 in Langendiebach/today
Erlensee shows that Jakob Lach registered a
retail business for cigars. His first step to being a fully qualified
merchant and entrepreneur? Merchant school in the
morning and salesman in the afternoon? The decision to
target “diamond cutters” as his cigar customers turned out
to be the perfect choice for his further career. He still knew
a few diamond-cutting shops in and around Hanau which
20 no. 3, August 2022

news & facts
the group who should be as “neutral” as possible. They chose
Jakob Lach. He was well known, a good communicator, and
he knew something about diamond cutting. In 1922 a small
group of travellers, with their speaker Jakob Lach, went to
visit the diamond company of Joseph Asscher (Amsterdam
Royal Asscher Diamond Company), already well renowned
since 1902, to secure some new orders.
My father told me that Mr. Asscher greeted them personally.
Yes, he had enough diamond material to have it cut to
brilliants in Hanau, he was seriously interested. They could
immediately take a large batch with them, but one of the
Hanau representatives would have to sign a personal pledge
of responsibility. After a brief discussion it turned out that
none of them wanted to give such a personal guarantee for
the others. So the delegation returned empty-handed.
Excerpt of business registration, 1919
had hesitatively restarted business with the help of re turnees
from war. He visited them on his bicycle. He “chatted” a
little here and there, looked over the grinders’ shoulders and
learned to distinguish the good craftsmen from the lesstrained
diamond cutters.
From then on Jakob was known as frequent “guest” at
all diamond cutting shops he visited. The closer the 1920’s
came the less work – i.e. materials – was available for diamond
cutting shops, so as to keep their cutters employed.
Reparations, as demanded by the victorious powers in the
treaty of Versailles after World War I, did the rest. At that
time the German Reich resorted to printing more and more
money, and circulation reached sky-high numbers, up to
tens of trillions. This went so far that in 1923/24 paper mills
could no longer meet the demand of the money printing
machines, so companies had to use value vouchers to substitute
money.
September 1922, due to continuous currency fluctuations,
it was reported that official bodies set prices in-kind; in
Weimar and Naumburg, for example, tuitions, electricity, gas
and doctors’ fees were paid in-kind. I have been told that in
this time the owners of diamond cutting shops got together
in order to try to find a common solution.
From the perspective of potential customers in Holland
and Belgium it was then advantageous to place orders in
the German Reich; wages were low and there was no shortage
of workers. All in all simple, if the diamond business, due
to the quickly resulting high value, was not built on a special
principle: trust!
On the way to Amsterdam
The consulting Hanau entrepreneurs thought the same.
In preparation for their excursion to a potential prospective
customer in Amsterdam, they agreed to select a speaker for
You are my man, Mr. Lach
Jakob Lach, now 28 years old, had listened to all of this,
thought about it, and decided to ask his father whether he
would pay out his share of the inheritance. Jakob Lach returned
to Amsterdam with a few gold marks in his pocket,
this time on his own. He offered Joseph Asscher his inheritance
as a guarantee so that he could take the diamond
material with him in order to save jobs. Apparently Mr.
Asscher was very touched by the young man’s offer. He
answered along the lines of “…you will understand that
the amount you offer is not sufficient as a guarantee for the
value of the stones you want to take with you. But I like you.
I trust you. You are my man, Mr. Lach.”
So Jakob Lach returned to his new office on Glockenstrasse
in Hanau with a large quantity of diamonds* to be cut. If we
want to put it that way, this was the founding date of today’s
Jakob Lach GmbH & Co. KG, now LACH DIAMANT®.
*note:
The rough diamonds were entrusted to the
contractor’s (in this case Jakob Lach’s) safekeeping.
The contractor’s job was now to view the diamonds
one by one and, when e.g., cutting them to brilliants –
57 facets, board included – to achieve the best
possible weight in carat (1 ct = 0.2 gram).
A weight loss of approximately 55 % was deemed
acceptable when cutting brilliants. Each stone which
could be cut with a smaller loss than 55 % would
increase the profit or the resulting final net weight.
As a general rule, business partners would split the
difference between the accepted weight loss of 55 %
and the final net weight; in addition to the calculated
costs (wages) for polishing the diamonds the contractor
was paid his share as a bonus. This was a win-win
situation for both partners. The bigger the contractor’s
know-how when viewing the diamond material before
cutting, the more appealing it was for the client to
enter a lasting business relationship with him.
no. 3, August 2022
21

news & facts
Prevailing in difficult times
His hour had come. Now Jakob Lach could use all his knowhow.
His experience as diamond cutter, and equally important,
from his days as a salesman, his expertise in judging
a cutter’s professional skills which can vary greatly between
individuals.
First company excursions 1923/1924:
a bus trip to Alzenau (lower Franconia)
The available batches were examined stone by stone and
then transferred to different cutting shops especially chosen
for the job; at first this was necessary, because he did not
have his own diamond cutting business. However this would
change quickly, as documented on photographs of the first
company outings around 1923/24.
The exceptionally well-equipped diamond cutting and
polishing shop was located in this timber-framed house,
renovated in 1935, destroyed March 19, 1945
that during this high time of the mid and late 20’s some diamond
cutters only worked four days a week.
Until the end of the 1930’s Jakob Lach could employ approximately
600 diamond cutters. Half of them in shops
he now owned – in Langendiebach/today Erlensee, Nieder-
Rodenbach and finally in Hanau, Steinheimer Strasse/corner
Römerstrasse; the latter a timber-frame building, beautifully
restored by Jakob Lach (which unfortunately fell victim to the
destruction of Hanau).
Another estimated 300 diamond cutters were employed
in sub-contractor shops in Palatine (Idar-Oberstein), the
Odenwald area and far into the Kinzig valley. The great
“depression” at world markets at the end of the 20’s and
the beginning of the 30’s required creative means of payment
– payment in-kind, became more and more common.
Diamond cutting shop in Langendiebach/today Erlensee
at the end of the 1930’s
Despite excessive inflation and general unemployment it
may be noted, that from 1922/23 onward the diamond cutting
profession was doing well, if not very well. Of course
it was fortunate, that the clients were not from within the
German Reich, but from Holland or Belgium. Invoices were
not issued in Reichsmark but in the clients’ currencies or
US dollars. This brought in foreign currencies, independent
of the turbulent situation in Germany. This meant that also
workers were well paid. Contemporary witnesses even report,
It is known that Jakob Lach had to accept “industrial
diamonds” from a Belgian customer as payment instead of
currency. Possibly the beginning and “push” towards the
diamond tool as the future business purpose. The extent of
these alternative payments in-kind must have been so extensive
(since 1936), that Jakob Lach now registered his business
under the trade name “German Industrial Diamond Retail
Jakob Lach” (Deutscher Industrie-Diamanten-Vertrieb Jakob
Lach), with represantives in the Madgeburg/Chemnitz/
Leipzig area (previously known as the machine construction
triangle) and Hessen/Saarland; companies like Opel
Rüsselsheim were among his customers.
How does this story continue? Find out more in Horst
Lach’s next article…
Horst Lach
further information: www.lach-diamant.de
22 no. 3, August 2022

news & facts
Strategic partnership
The headquarters of TSCHUDIN AG
in Grenchen, Switzerland
TSCHUDIN AG, a global technology leader in highprecision
centerless cylindrical grinding, and the
UNITED GRINDING Group, one of the leading
manufacturers of precision machines for grinding,
eroding, lasering, measuring and combination machining,
are entering into a strategic partnership
involving cross‐ownership.
The aim is to provide their customers with even more comprehensive
support by offering complementary grinding
solutions and using shared sales networks. TSCHUDIN
AG specializes in the manufacturing and global sale of
high‐precision centerless cylindrical grinding machines.
Thanks to the strategic partnership with the international
UNITED GRINDING Group, which offers a wide range of
grinding solutions, from surface and profile grinding to cylindrical
grinding and tool processing, the cus tomers of both
companies benefit from a complementary pro duct portfolio.
The companies continue to operate economically independently,
but benefit from additional synergies in sales.
“The UNITED GRINDING Group is globally strongly
positioned. With the foundation of our TSCHUDIN sales
company in China in 2019 we further expanded our international
presence. We want to continue on this path,” says Urs
Tschudin, shareholder of TSCHUDIN AG.
“We are delighted to be working with TSCHUDIN as a
strong partner who ideally complements our range with
its centerless grinding machines. As part of this strategic
partnership, we provide the complete range of cylindrical
grinding machines to our customers,” says Stephan Nell,
CEO of the UNITED GRINDING GRINDNG Group. “We
look forward to a close long‐term partnership.”
further information: www.tschudin.swiss
Scansonic MI takes over
its own sales efforts
Scansonic MI, one of the world’s leading manufacturers
of laser processing optics, is reorganizing its
global sales structure.
Dr. Axel Luft
As of July 1, the company is working with its own branch
offices in its key markets of Germany, China and the USA.
Sales activities in the rest of the world are supported by
experienced sales partners and distributors. In recent months
the Scansonic sales team has been significantly expanded and
restructured to support this new arrangement.
These efforts are part of Scansonic’s continued growth
strategy. The company’s products for laser-based metal
processing require intensive consultation, and are generally
adapted to each customer’s individual production processes.
Dr. Axel Luft, managing director sales & marketing
at Scansonic, explains the benefits for customers:
“With this new structure, we are now able to directly provide
to our customers the technical knowledge and service
they need. Our experienced sales force keeps close to our
customer base around the world, and also works closely with
Scansonic specialists from the product teams and the
application laboratories.”
further information: www.scansonic.de
no. 3, August 2022
23

news & facts
academy/fairs
New Grinding academy launched
UNITED GRINDING and TITANS of CNC, a manufacturing
group of part-makers, influencers and educators,
have collaborated to launch the all-new
Grinding Academy.
Much like TITANS’ existing machining and aerospace academies,
the Grinding Academy will offer free online courses for
teaching and training the next generation of machinists.
“We’re so excited to be teaming with TITANS of CNC
on their Grinding Academy,” said Paul Kössl, global head
of marketing and business development at UNITED
GRINDING Group. “The precision and quality made possible
by CNC grinding is something that more manufacturers
should know about. The academy will showcase all of
that power and potential, while also teaching viewers how to
harness it.”
TITANS of CNC has four UNITED GRINDING machines
on its shop floor in Texas: the BLOHM PLANOMAT XT profile
grinder, the STUDER favorit and STUDER S41 cylindrical
grinding machines, and the WALTER HELITRONIC
VISION 400 L tool grinder. These machines will be the first
tools used to create content for the Grinding Academy. The
Grinding Academy launched in June 2022.
further information:
www.titansforgrinding.com // www.grindingacademy.com
TIMTOS 2023 to unveil Metaverse and EV
The world’s third largest machine tool show, Taipei
International Machine Tool Show (TIMTOS), scheduled
for March 6 - 11, 2023, will debut innovations and
applications in EV and Metaverse at Taipei Nangang
exhibition center halls 1, 2 and TWTC hall 1.
Since 2019 TIMTOS became the third largest machine tool
show in the world. Notably, themed with “Green Machine
Tools,” “Smart Machinery,” “Flexible Manufacturing,” and
“Digital Simulation.” TIMTOS 2023 is returning to feature
innovations and applications in EV and Metaverse sectors.
The exhibition will be also showcasing a full line-up of hybrid
events, including online and offline procurement matchmaking,
live broadcasting, forums and seminars. It is worth
noting that, aside from a physical trade show, an online exhibition
will also be available for one month.
The show will present the ecosystem of metal processing,
from key components to smart manufacturing solutions. According
to the organizer TAITRA, TIMTOS will focus on the
issue of “low-carbon supply chains.” Smart solutions that integrate
the concepts of digitalization and carbon reduction
will be highlighted at the show.
Taiwan ranked third in the world’s machine tool exports in
2021, total exports of machine tools in 2021 reached US $ 2.78
billion, a phenomenal increase by 29.1 % compared to 2020.
What’s more, markets recorded more than 50 % growth in
Turkey, the Netherlands and Italy. Unsurprisingly, in anticipation
of continuing global demand, Taiwan machine tool
outputs will increase in the coming while the supply chain
restructuring has generated new business opportunities.
further information: www.timtos.com.tw
24 no. 3, August 2022

fairs
news & facts
A stable trend towards automation
in the metal cutting industry
Since years automation has kept manufacturing costs
low and processes stable for metal working businesses
carrying out serial production. Nowadays, however, the
market requires a high degree of product individualisation,
resulting in smaller batch sizes. The benefits of
automation are therefore particularly welcome when it
comes to implementing flexible production processes
for small quantities.
The following article provides examples of the solutions to
be presented by exhibitors at the International Exhibition for
Metal Working (AMB) in Stuttgart September 13 - 17, 2022.
The market for automation, robotics and handling technology
will continue to grow. The AMB exhibitor Grob is convinced
concerning five-axis machines. Grob believes that the
machines will have integrated additional NC axes, to provide
additional options such as feed operations. Turning and milling
machines with hydraulic clamping will combine different
types of machining with the possibility of automation. Grob
sees automation concepts moving further in the direction
of industrial robots to replace more rigid concepts and integrate
additional operations such as deburring, cleaning and
assembly. These developments are already playing an important
part in the further development of universal machines
and automation solutions, and that will continue.
Fast mechanical connection and communication
Flexibility is a top priority for clamping technology manufacturers
too. The AMB exhibitor Schunk can pride itself on offering
quick, simple automation solutions using lightweight
robots. The MTB application kit is designed to provide an
easy introduction to partial automation with cobots. It can
be used to load machines, execute general handling tasks or
quality assurance or even carry out assembly steps. Schunk
also offers single-grip kits that automatically load machines
even in restricted spaces. The double-gripper kit, on the other
hand, loads and unloads on a cycle, thereby increasing machine
productivity. In the cutting machine itself the clamping
force block kit ensures a frictionless interplay between the
gripper and automated clamping force block.
Existing machines to be automated
Also the clamping technology experts at Hainbuch move towards
automation, and not just for new systems. Loading robots
that can perform simple setup tasks such as fitting the
chuck head, the clamping device or tools also add increasingly
to the automation of existing machines. Hainbuch will be
bringing its AC line for automated changing of clamping devices
on machine tools specially to AMB in September. AC,
which stands for Automated Change, enables the automatic
setting up and production of workpieces with different clamp -
ing diameters, clamping profiles and clamping depths. A set
up robot cell is on display, showing a complete automation
solution for manufacturing cells for milling, turning, grinding
or assembly. This will allow visitors to see the full picture,
from clamping device, robot cell, assembly device, gripper
and mounting to sensors and software.
Collaborative and lightweight
The robot manufacturer Fanuc also sees high demand for collaborative
robots on the European market. Shinichi Tanzawa,
president and CEO of the Fanuc Europe Corporation, is confident
of his position at AMB. The company has recently expanded
its product range to include three new collaborative
lightweight robots from the CRX series. These cobots supplement
Fanuc’s existing CR and CRX cobot product line, which
now comprises a total of 11 models that can handle loads
from 4 to 35 kg.
Impossible without software
Intelligent software is the key to successful automation for
the complete machining provider WFL Millturn Technologies.
In combination with suitable automation solutions, it not
only loads and unloads workpieces, it also fully automates the
setup of processing machines with tool and clamping device
changes. The automation expert Frai, part of WFL Millturn,
is developing highly flexible robot systems for this purpose.
At AMB 2022 WFL will be specially showcasing its new
turning, drilling and milling center M20-G Millturn with
gear skiving technology, the intCELL automation solution
and integrated sensors. Using integrated loading, WFL
has reduced space requirements by 50 % compared to
those of a conventional manufacturing cell. The integrated
loading of the M20-G is designed for chuck parts with
Ø 300 mm and workpiece weights of up to 15 kg. For shaft
parts it can take a workpiece Ø 100 mm and a workpiece
length of 300 Ø mm.
Maximising autonomous running time
Hermle offers automation solutions ranging from easy-touse
pallet changers and handling systems for part stocking
using pallets to premium solutions with a diverse range of
robot systems and, increasingly, linear chains, as head of
marketing, Udo Hipp, explains at the trade press conference
before AMB.
The RS 1 robot system is a fully fledged combination cell
for pallet and workpiece automation. The goal is flexibility
and productivity: The rack storage concept ensures a particularly
high autonomous running time, while gripper and tool
changes take place automatically and the fully fledged setup
station allows pallets and workpiece carriers to be set up
while the machine is running. According to Hipp this makes
the RS 1 the perfect automation solution for many businesses.
The robot system can be used with one or with two machines
connected together for maximum output. It can also be converted
from one to two machining centers or expanded with
a third rack module, a washing system, a measuring machine
or a driverless transport system (DTS).
further information: www.amb-messe.de
no. 3, August 2022
25

processes
High precision HSC machining in mold making
for medical technology
Excellent results in graphite, copper
and hardened steels
The production of injection molds for medical
technology is increasingly in focus, due to the current
situation. Globally the demand for medical products
is growing rapidly. On top of increasing production
capacities, special attention is also being paid
to tolerances and surface finishes. With this in mind
the machine tool supplier GF Machining Solutions and
the precision tool manufacturer ZECHA Hartmetall-
Werkzeugfabrikation GmbH have committed themselves
to a project that examines four different automated
manufacturing processes for injection molding,
their qualities and running times.
Graphite electrode (GF Machining Solutions)
Klaus Bruder (ZECHA; left),
Alexander Siegmund (GF Machining Solutions)
The GF Machining Solutions machining equipment and
ZECHA mills offer four cost-effective options with different
surface finishes for the implementation of cavities in a mold
insert made of 1.2343 with a hardness of 52 HRC. The first
manufacturing process for producing a cavity is EDM, using
a graphite or copper electrode. This complex manufacturing
process consists of hard milling of the mold insert, electrode
milling and sinker EDM. The process of producing an
injection mold, using a graphite electrode, takes just under
57 minutes in total, but has many stages. Using the ZECHAmanufactured
tools from the SEAGULL® 1) family on the GF
machines, the Mikron MILL S 600 U and the FORM X 600,
users benefit from tolerances of ± 0.005 mm as well as surface
finishes of Ra 1.6 µm and VDI 24. It is the polymer concrete
machine bed with a high thermal inertia and excellent
dampening properties that makes the Mikron MILL S
series so special. All five axes are equipped with direct high
precision drives (X-, Y-, Z-, B- and C-drives) and thus enable
high speeds of up to 100 m/min and µ-accurate positioning.
Thanks to a spindle with OptiCool or CoolCore technology,
the sophisticated temperature management system with
its cooling circuits ensures the optimum cooling of all heat
sources and the machine bed. The stable thermal system, the
integrated automation and the high-performance guarantee
process reliability, superior productivity and maximum part
precision.
SEAGULL® 1) tools are highly stable ball and torus mills
with an extremely short cutting edge and special geometry to
minimize the cutting pressure in graphite electrode production.
The patented (EP 2 540 427 B1/DE 10 2019 122 039 B31),
very short cutting edge of the SEAGULL® mills together with
its specially developed combination of carbide, diamond
coating and geometry, enables the smooth milling of graphite
and other hard-brittle non-ferrous materials in dry and
wet machining. SEAGULL® high end mills from the 567 and
577 series especially offer small tolerances. Each tool is measured
and the packaging is labeled with the actual values. The
SEAGULL® quality mills of the 568 and 578 series are available
for price-aware users who focus on excellent quality. The
torus mill 576.T3 is new to the SEAGULL® family. With its
three cutting edges it is unique in the market and, as a result
of its combined geometric features and cutting edge dimensions,
has a lot of clearance for swarf removal and high removal
rate when roughing as well as the finest contact rations
when finishing.
When carrying out the procedure with a copper and graphite
electrode, the production time is extended to 3 hours and
26 no. 3, August 2022

processes
57 minutes. Also here the machines from GF Machining
Solutions equipped with solid carbide torus and ball end mills
from the 556 series enable ZECHA tolerances of ± 0.005 mm
and surface finishes of Ra 0.22 µm and VDI 7. The solid
carbide torus end mills for HSC machining of non-ferrous
metals are available as a short version with clearance and
precision-ground, polished cutting edges and flutes. For
precision in the µ-range ZECHA manufactures this tool series
uncoated as standard or with a coating, optimally
matched to the machining, on request.
High-speed milling is another manufacturing process for
injection molds. In the first two stages roughing is done with
a Ø 3 mm ball mill and feed rates of 4 m/min. In contrast to
machining with a larger tool, the short machining times reduce
set-up times and costs, as are the number of tool places.
Almost 90 % of the total machining time is spent on finishing,
which places the highest demands on the tool in terms of
maximum surface quality, accuracy and tool life. In the three
machining stages, tolerances of ± 0,005 and surface finishes
of Ra 0.1 µm and VDI 0 were achieved in 60 minutes. The
high-performance end and ball mills from the PEACOCK
tool series used on the Mikron MILL S 600 U reach their full
potential when machining soft, hard and powder-metallurgical
steels up to 70 HRC. The PEACOCK family is the innovation
in the ZECHA hard milling cutter range for high-speed
machining in mold making. The multi-fluted PEACOCK ball
nose and torus end mills are available in different sizes: series
581P ball nose mills from Ø 0.2 to 12.0 mm and series 583P
and 597P torus mills from Ø 0.2 to 6.0 mm and 0.8 to 6.0 mm
respectively. The new 599 series complements the PEACOCK
line with immediate effect with new ball and torus mills
from Ø 0.1 to 12 mm. It also includes the new 599.F4 and 599.
F6 lines – special high performance end mills that stand out
from the competition: the 599.F4 with a finely machined protective
radius of max. 0.05 mm and the 599.F6 with a defined
grinding radius, providing extra edge protection.
1)
SEAGULL ® Products
are protected by the patent EP 2540427B1
in the following countries:
DE, AT, CH, LIE, CZ, FR, GB, IT, NL, PL, PT, TR.
The SEAGULL ® series 576.T3 is additionally protected
by the patent DE 10 2019 122 039 B3 in Germany.
Copper electrode (GF Machining Solutions)
The new mill design guarantees a high machining efficiency
through its great performance and wear resistance for a
wide range of materials, alloys and material hardnesses up
to 70 HRC. A new coating technology in combination with
the right solid carbide substrate, a stabilized geometry, finest
micro-geometry as well as rounded shank transitions cover
further applications in all shapes and component hardnesses.
Even high alloy, soft materials can be dry-finished with cooling
lubricant just as well as high-strength, hard materials, not
only when roughing but also semi-finishing as well as fine
finishing with the highest precision and component shape accuracy.
Minimized friction, thanks to optimized and homogenous
coating surfaces as well as excellent coating adhesion,
also results in better repeatability and safety during use. The
resulting potential for tool service life and surface finishes
offers significant added value to the customer.
The new CBN line 950 comes as a ball nose and torus end
mill ranging from 0.2 to 2.0 mm. The high hardness of the
substrate contributes to an increased service life of its form
and dimensional accuracy. Its precise geometry results in an
ideal finish on the component. Also the form contributes to
the stability of the cutting edge.
When complemented with digital laser technologies,
aesthetic and functional texturing can be implemented both
easily and reproducibly. Even complex 3D geometries, including
precision parts, are precisely textured, engraved, structured,
marked and labeled. Using the LASER P 400 U from
Schorndorf, the last step in the aforementioned process, finishing,
can be replaced with laser cutting. Compared to the
milling process with integrated finishing, the production
time is reduced to 37 minutes for the production of the injection
mold. With the intelligent combination of milling and
laser texturing, these two experts have created an efficient
alternative for surface finishes of Ra 0.6 µm and VDI 16 along
with the lowest tolerances of ± 0.005 mm.
GF Machining Solutions and ZECHA’s product portfolios
cover together all manufacturing processes, offering excellent
end results. For customers this cooperation results in a
wide range of possibilities, including the production of injection
molds for medical technology. The subsequent supply
chain efficiency enables customers to benefit from a genuine
cost reduction. GF Machining Solutions and ZECHA
are constantly working on optimizing EDM technologies to
increase machining speeds and reduce electrode wear with
highly polished surfaces of Ra 0.1 µm. As a result, they have
the most economical and highest quality solution ready for
every application – with specified tolerances, surface qualities
and production times. They will continue to optimize their
machines and tools, in order to guarantee their customers the
best possible added value and support.
further information: www.zecha.de // www.gfms.com
no. 3, August 2022
27

processes
Seeing mobility change as an opportunity
Combined drive technologies and e-mobility
require a multitude of precision-ground components.
The manufacturer of high-quality grinding
technology, Fritz Studer AG in Thun, considers itself
ideally equipped to meet this requirement with its
productive machining concepts and high-quality
grinding machines.
Mobility change will not cause the sharp drop in production
initially feared in the machining sector. The specialists
at grinding machine manfuacturer STUDER in Thun
are convinced of this. As Sandro Bottazzo, chief sales officer
(CSO) at STUDER, points out, the range of components to be
produced will slowly and continuously change over a number
of years or even decades. To illustrate this, he cites the
expected quantities of passenger cars sold worldwide and the
shares of the respective drive technologies. “Based on various
analyses, we assume that the combustion engine will
con tinue to play an important part over many years and in
numerous regions of the world”, states Sandro Bottazzo.
“The general demand for individual mobility is continuing to
increase worldwide, which offers corresponding opportunities”,
says Sandro Bottazzo.
Wide variety of drive technology
keeps market stable
In the coming decades a wide variety of drive technologies
will be available in parallel. In addition to purely battery-powered
electric engines, diesel engines with exhaust
gas cleaning, hydrogen engines, hybrid engine technology (a
combination of combustion and electric engine) and electric
drives with power generated by fuel cells will still be used to
power cars and trucks. Further drive technologies will even
be added where possible. Meaning for production companies
that there still is a great demand for precision components
for the drive train. This includes shafts, axles, bushings, gear
wheels and compressor wheels, camshafts and crankshafts. In
addition, the autonomous vehicles currently under development
will soon be produced on a larger scale. For these the
automotive industry additionally requires a wide range of
different precision components in large series.
Complex systems increase demand
Efficient drive technologies usually require very complex
systems. This applies to hybrid and electric drives, for example,
which recover electrical energy during regenerative braking.
For machining this also means the production of an increasing
number of usually very complex components. “This
opens up additional opportunities. We will continue to monitor
the market carefully, so that we can further develop our
products accordingly”, underlines Sandro Bottazzo. The already
well-known applications for innovative grinding technology
include components for CVT transmissions (used
primarily in hybrid drives), rotor and gear shafts for electric
Exploded view of electric engine
(chesky AdobeStock)
engines, shafts for turbochargers, compressor shafts for fuel
cells, shafts and valves for hydrogen engines, ball screws for
electric steering systems as well as various precision tools
for cost-effective machining of housings for electric engines.
Likely there is significant growth in the latter.
Productive and cost-effective
with sophisticated grinding concepts
As Sandro Bottazzo reports, Fritz Studer AG offers safe and
reliable grinding technologies for the specified components.
For example on a CVT transmission the primary and secondary
shaft must be ground. This is done in a high-precision
process with the shortest machining and processing
time on a STUDER S41 grinding machine, in a single
clamping. Even the ball track grooves in the shafts and in the
holes of the sheaves can be ground in a single clamping. A
vertical spindle, which is mounted on the proven Y-axis, is
used on the S41 grinding machine for this purpose. A special
unit, developed by STUDER, is used for high-precision
grinding of the ball tracks in the sheaves. Grinding in a single
clamp ing, together with fully automated processes, ensures
extreme ly cost-effective production. This applies to the
loading, unloading and measurement of workpieces, as well
as adaptive control of grinding processes. The latter in particular
contributes to the highest precision and reliability.
Sandro Bottazzo stresses: “STUDER provides manufacturing
companies with complete systems of matching components”.
Toothed racks for electric steering systems
Electric steering systems, which are specifically required for
autonomously controlled vehicles, operate with precisionground
threaded rods. The steering motion is driven by balls
rolling inside. This “ball screw” is advantageously ground
from the solid on STUDER grinding machines. Compared
to other machining technologies a significantly better surface
28 no. 3, August 2022

processes
Exploded view of conventional combustion engine
(Vlad Kochelaevskiy AdobeStock)
quality is achieved, with comparable machining times. The
resulting advantages are reduced steering noise and a considerably
longer lifetime of the steering gear. The dressing unit
exclusively developed by STUDER, WireDress® (wire erosion
of the profile), is used for dressing. WireDress® enables
completely new possibilities when grinding with metalbonded
CBN and diamond grinding wheels: not only does
this electro-erosive integrated dressing technology save a huge
amount of downtime, it also enables sintered metal bonds
to be dressed with the highest precision in the grinding machine
at full wheel speed.
High-speed compressor wheels for fuel cells
Fuel cells require electrically driven compressors, which
operate at very high speeds. The integrated shafts and sheaves
must therefore be manufactured with high precision. In addition,
they comprise materials that are difficult to machine.
STUDER has developed its own grinding concept for these
requirements. The shafts can be pre-machined at high speed
on an S41 cylindrical grinding machine by means of peel
grinding. The CBN wheels are dressed with the WireDress®
technology exclusively developed by STUDER. Thanks to
a synchronizable tailstock, the universal cylindrical grinding
machines can reliably accept components of different
dimensions.
Components for electrically driven turbochargers
Small, powerful and extremely efficient combustion engines
can only be achieved by turbochargers. But they only work
with an adequate exhaust gas flow and pressure, i.e. with sufficiently
high speed of the combustion engine. Only then
can the compressors build up the necessary pressure to convey
high quantities of combustion air into the cylinders. Insufficient
air flow and pressure at low engine speed is commonly
referred to as “turbo lag”. In order to prevent or reduce
this, engine manufacturers are increasingly using socalled
e-boosters, i.e. electrically driven charge air compressors.
The integrated engine shafts can be advantageously
ground on universal cylindrical grinding machines, such as
a STUDER S31, for example. First the rotor shaft is ground
on the diameter and at the shoulders. This requires a special
clamping device to carry the workpiece. After grinding, the
magnets are affixed. A titanium alloy sleeve is then pressed
on by the magnets. The sleeve must now be externally ground
precise to the diameter. This can be advantageously carried
out on an S33 universal cylindrical grinding machine.
This Tools for engine housings
As Sandro Bottazzo adds, increasing electromobility
means that in particular tools must be ground with
high precision, in addition to the actual vehicle components.
STUDER has developed a suitable concept to achieve
the required accuracies; the relevant STUDER grinding
machine is equipped with the LaserControl TM in-process, an
optical and contact-free measuring system. The “Closed Loop
Process” adaptive control controls the grinding process.
further information: www.studer.com
no. 3, August 2022
29

machining center
Welcome to the Machine.
Farewell to the past…
Footprint 1,425 x 1,875 mm. Height 2,070 mm.
Free over-corner access. New operating concept. Simple
programming. Unparalleled changeover times.
Maximum reduction to the essentials. Namely tool
grinding. This is the new Multigrind® Radical from
Haas Schleifmaschinen.
Multigrind ® Radical in action:
big on the small scale
The response to the two all-in-one tool grinding machines
exhibited at GrindingHub was correspondingly great. This is
not surprising, since maximum precision for rotary and plate
tools is offered in the smallest possible space. This means that
all customer requirements can be produced extremely flexible
on just one tool grinding machine. Milling cutters, inserts,
drills as required. In large quantities or as very small series
from batch size 1 to 1,000.
In particular, the award-winning control concept created
a good mood among the trade audience. This is because the
consistent decoupling of operation from the machine allows
a level of freedom that has never been seen before. The Multigrind®
Horizon grinding software runs in the company’s own
network and is executed via laptop, tablet or cell phone. This
brings unprecedented mobility to the machine operator. And
automated unmanned series production becomes the production
standard with this approach. Parameterization, tem-
plates and ERP information form the data basis. Programming
is super simple and makes very fast production changes
possible. Just provide parts and start grinding. Additional
performance, fast service, current updates, physical information,
safety instructions, process parameters and much more
can easily be retrieved from the cloud on request.
Multigrind ® CB XL:
complex workpieces up to 3,200 millimeters
The absolute contrast to the Multigrind® Radical was the
Multigrind® CB XL 3200 at the Haas Schleifmaschinen trade
show booth in Stuttgart. This is because the 5-axis CNC
grinding center Multigrind® CB XL sets new standards in
terms of precision for the complete machining of workpieces
up to 3,200 millimeters in length literally. Production in a
single setup is particularly attractive for manufacturers of
large tools, such as shaft parts with splines or gear cutting
tools. But the oversized high-tech grinding center has also
become a pacesetter in the machining of long, slender parts
such as landing gear parts for aircraft, turbine components,
ball screw drives, racks and guideways. Its consistent symmetrical
design gives the Multigrind® CB XL the necessary
stability and rigidity to meet demands in terms of precision.
The Trossingen-based precision specialist demonstrated
impressively at GrindingHub that the software takes manufacturers
of highly complex XXL workpieces a decisive step
further. Because the Multigrind® Styx visualization software
enables digital pre-grinding. With visible machining heel.
With all details, unevenness and transitions. Even residual
ripples in the workpiece surface are displayed, for most precise
adjustments and corrections and the final polish even
before the first. The advantage is clear: expensive blanks and
machine hours are saved.
Multigrind ® Multimation:
when turnkey grinding is not enough any longer
The developments of recent years clearly show that the requirements
in grinding are constantly increasing. However,
this does not only apply to the complete machining of complex
workpieces, but also to the upstream and downstream
production processes. The key to success here, too: the software.
The decisive factor here is the interface. In the future
the Multigrind® Multimation will take over control.
Production in a single setup is particularly attractive for
manufacturers of large tools, such as shaft parts with
splines or gear cutting tools
Multimation enables manual and automatic workflows,
completely customized, just as customers need it, and without
any losses in process times. The interface to the ERP
30 no. 3, August 2022

machining center
The new Multigrind® Radical revolutionises the future of tool grinding
system, customized of course, just like the process. Located
in the company network and always there.
The advantage is obvious: It will be much easier than before,
because the mapping of the setup processes was inconvenient
up to now. With Multimation the entire manufacturing
process can be mapped and controlled. Process components
such as manual scanning, automation solution and
cleaning system or labeling machine, etc. can be digitally
removed and added as required. Good for productivity,
individual process components can be bypassed with Multimation
in the event of a malfunction and can be controlled
again after the malfunction has been rectified. Intervention
in the job or order lists thus becomes standard practice,
resulting in a significant reduction in downtime.
Hardware and software from a single source:
simply unbeatable
In addition to the Multigrind® Radical, the Multigrind® CB XL
and Multigrind® Multimation, the precision specialists from
Trossingen had their proven all-rounders and problem solvers
in their luggage: the Multigrind® CU, the Multigrind® CA and
the Multigrind® CB. The performance of the universal grinding
centers was demonstrated by the production of rotors
for pelletizing, the manufacture of inserts and skiving tools,
and the resharpening and manufacture of hobs. Each workpiece
in the production process is demanding in itself. With
the successful interaction of hard- and software, however, it
is quite simple. Because with hardware and software from
the same source, there is no such thing as too complex for
economical production.
The 5-axis CNC grinding center Multigrind® CB XL sets new standards in terms of precision
for the complete machining of workpieces up to 3,200 mm in length literally
further information: www.multigrind.com
no. 3, August 2022
31

machining center
Innovations in action
and all-round expertise
PERFORMANCE MEETS PRECISION: the new
claim from the CHIRON Group is also a promise,
which will be fulfilled at AMB 2022 with the special
combination of performance and precision in products,
solutions and services. For sustainably productive
processes in all industries. Milling and mill-turning,
additive manufacturing, automation, turnkey, digital
solutions, services, refurbishment.
Machine highlights live in action
The CHIRON Group will showcase its expertise in the fields of
milling and mill-turning with live-action demos of three innovative
machining centers: the DZ 22 W five-axis efficiency
booster with HSK-A 100 interface and spindle distance of
600 mm for the machining of complex components for the
automotive and aerospace industries. An ultra-compact plugand-play
solution consisting of the Micro5 machining center
with the Feed5 handling system for automated, high-precise
micromachining. And the new MT 715 two+ with integrated
workpiece handling for multifunctional complete machining
from the bar – also in unmanned shifts.
The DZ 22 W five-axis in action – a machine of the future,
for complex components for e-mobility and aerospace
The new MT 715 two+ with integrated workpiece handling
for multifunctional complete machining from the bar
Plug-and-play solution for automated micro machining:
the Micro5, combined with the Feed5 handling system
A special kind of cinema experience
To see other highly productive machining centers in action,
it is also worth visiting the «CHIRON Group cinema», which
will be showing live broadcasts from Tuttlingen, Germany,
twice a day. Or take a look in the interactive showroom,
where you can see the STAMA 733 series for heavy mill-turning
and drilling operations as well as 5-axis simultaneous
machining.
In an exclusive preview, visitors get a sneak peek on the
latest innovation – AM coating. This industrial system applies
anti-corrosion and wear-resistant coatings to brake disks, for
hybrid or electric cars, for example.
The CHIRON Group will be presenting tomorrow’s production,
today, as digital system of the SmartLine software
portfolio. How smart and intelligent are the ProtectLine and
ConditionLine modules in practice, for example? The experts,
together with two cooperation partners, will be demonstrating
this on the DZ 22 W five-axis double spindle machining
center. Visitors can then see the actual added value offered by
automated tool handling with ZOLLER and coolant management
with MOTOREX.
AMB 2022, hall 10, booth A41
further information: www.chiron-group.com
32 no. 3, August 2022

machining center
Como Industries quintuples pin gauge
output with the TSCHUDIN CUBE 350
TSCHUDIN covers a very wide range of machined
workpieces in centerless grinding: from the smallest
wires for medical technology to truck axles weighing
150 kg.
“It changes our way of working completely”, says Sophie
Demesse, CEO of Como Industries, about the purchase of the
compact, centerless TSCHUDIN CUBE 350 centerless grinding
machine. Como Industries, headquartered in Courbevoie
near Paris, produces pin gauges, hydraulic nuts, and other
high‐accuracy pieces for well‐known customers such as
Airbus, Michelin, Thales Group or Safran. The CUBE 350
will be used for the production of high‐precision pin gauges.
Ms. Demesse: “On the old machine, we needed five hours
to manufacture 100 pin gauges with a very small diameter
and a precision of 1.5 micron. With the CUBE 350, we need
only one hour – a huge productivity leap!” The new grinding
machine convinces not only with speed but also with optimized
quality. “Before, we were not able to reach the same
kind of precision when it comes to diameters between 10 and
20 mm. These parts needed an extra finishing step. Thanks
to the CUBE 350, this extra step is no longer needed, which
boosts our efficiency”, underlines Ms. Demesse.
Concentrated know-how at AMB
The grinding experts of TSCHUDIN AG and the team
of Como Industries will take part at AMB exposition in
Stuttgart. Visitors can inquire about the successful cooperation,
exchange views with Ms. Demesse, TSCHUDIN shareholder
Urs Tschudin and CEO Iwan von Rotz, and of course
also witness the compact, award‐winning, three‐axis CNC
centerless grinding machine CUBE 350 on booth C11, hall 5.
New possibilities
With the upgrade of the machine park of Como Industries,
Sophie Demesse sees new possibilities for future development.
“Some pin gauges with larger diameters are rarely sold.
In future it might make sense to produce these on demand
instead of having them in stock.” Generally it is important
for the company to have a stock of most of their products in
the warehouse. Ms. Demesse: “If a customer calls and needs
a certain product urgently the next day, we will deliver. This
has been our service pledge since our founding in 1970.”
The purchase of the CUBE 350 had multiple reasons, explains
the CEO: “Firstly, we needed to upgrade our production
because the sales are going well. Secondly, young people in
this industry want to work on state‐of‐the‐art machines –
without this investment it would be much more difficult to
find and retain talent. It was a crucial step for us.”
After first contacts Ms. Demesse travelled to EMO Milano
in 2021 to meet with the TSCHUDIN team. In the discussions
Urs Tschudin, shareholder of TSCHUDIN AG, gave
his expert advice on how Como Industries could adapt its
production and increase efficiency. From that point on, the
The awardwinning
centerless
grinding machine
TSCHUDIN CUBE 350,
which has been produced for Como Industries
two com panies worked closely together, including the training
of Como Industries experts on the new machine in the
TSCHUDIN headquarters in Grenchen, Switzerland. “For us
it is important to stay one step ahead of our competition in
Europe, but also in Asia. The cooperation with TSCHUDIN
allows us to do so,” emphasizes Ms. Demesse. During the
important phase of needs analysis, Bernard Bouillé from BB
Tech also made a weighty contribution, being a distribution
partner of TSCHUDIN for France.
Versatile product portfolio
TSCHUDIN will present its versatile product portfolio as
a global technology leader in centerless grinding, at AMB
Stuttgart. “In addition to the CUBE 350 described above, we
will also exhibit another CUBE 350 with robot and a 400 eco-
Line. Workpieces of diverse sizes can be ground on our machines:
from the smallest wires for medical technology, whose
shape can only be seen under a magnifying glass, to truck axles
weighing 150 kg” reports Iwan von Rotz, CEO. While the
CUBE 350 is designed for machining small workpieces of up
to Ø 20 mm, the 400 ecoLine / proLine is ideal for machining
medium‐sized workpieces of up to Ø 150 mm and the 600
ecoLine / proLine can machine pieces of up to Ø 250 mm. The
maximum grinding wheel width is 500 mm.
The TSCHUDIN centerless cylindrical grinding machines
are used in all industries where mechanical components are
required with high accuracy and at economical unit costs –
from injection technology, hydraulics, automotive engineering,
drive technology, the bearing industry, medical technology
and toolmaking to aerospace. The materials machined,
such as steel, aluminum, glass, titanium, carbon, ceramics,
germanium or silicon, are just as versatile as the areas of
application.
AMB 2022, hall 5, booth C11
further information: www.tschudin.swiss
no. 3, August 2022
33

machining center
Planetary lapping machine for PCD and CVD
Coborn’s planetary lapping
machines are designed to polish
the top surface of PCD discs to a
flat, mirror finish
The PL5 is equipped
with 6 work heads as standard
Coborn’s planetary lapping machines are designed
to polish the top surface of PCD discs to a flat, mirror
finish. They can also be used to polish CVD discs and
PcBN. They consists of a number of independent work
heads which hold the discs against a large, horizontally
mounted planetary motion grinding wheel.
tains the disc at a uniform temperature to minimise disc
dishing. The PL5 is equipped with 6 work heads as standard.
Each arm is fitted with a double gimbal fixture to allow the
disc to self-level. The disc holders are motor-driven. The lapping
pressure can be individually adjusted.
The lapping or polishing of the top surface of PCD or
CVD components is desirable to produce a smooth surface
for chip flow and a good cutting edge for geometric
integrity. It also maximises edge life, enhancing the characteristics
of PCD and also minimises surface deviations over a
large PCD or CVD area.
The benchmark for the diamond industry
The RG9A is a fully automatic, high-precision
grinding machine designed to meet the sophisticated
demands of toolmakers working with hard and ultra-hard
materials, such as PCD, PcBN, carbides and
ceramics.
This versatile machine is supplied “robot ready” and the optional
Stäubli 6-axis robot can be added to the RG9A to facilitate
fully autonomous “lights out” production of tools.
The RG9A software is user-friendly where straightforward
programming blocks can be built step-by-step to produce
the tool forms and geometries you need. From simple,
single point shank tools to helical/radius multi-point rotary
tools, the RG9A has all the capabilities needed to minimise
tool production costs.
The RG9A is a fully automatic, high-precision grinding machine
It is impossible to use flood cooling when polishing large
areas of PCD as the discs ‘aqua-plane’ on the wheel surface.
Therefore, the lapping is a dry process and the wheel is internally
cooled using water from an associated water chiller.
Chilled water is also fed to the back of each disc. This mainfurther
information: www.coborn.com
34 no. 3, August 2022

machining center
The new productive STUDER machine S36
Due to the rapid development of e-mobility and other alternative
drive types, among other things, the demand for suitable
grinding machines for a new variety of components in vehicle
manufacture is also increasing. That is why STUDER has developed
the new S36.
It will be positioned between the compact S11 for small workpieces and
the S22 for medium-sized workpieces. Many features of the new S36
are similar to its very successful predecessor, which sold over a thousand
units. New functionalities for changing requirements supplement
proven concepts. “The demand for cost-effective grinding solutions for
medium to large series also remains consistently high in e-mobility
applications”, says project manager Martin Habegger. In addition to
vehicle manufacture the new machine will also be used in the hydraulic,
pump and toolmaking sectors.
The S36 has a fixed grinding head with grinding wheel angles of
0,° 15° or 30° available. The distance between centers is 650 mm and
the maximum workpiece weight is 150 kg. Proven components have
been used in the machine. These include a Granitan® machine bed and
a workhead with high-precision roller bearings.
Range of parts / market segment
The machine concept is designed for productive external grinding of
chuck and shaft components. STUDER serves many different industries
with the S36. Its field of application extends from die and mold
through the aerospace industry to the production of parts for the
hydraulic and automotive industry.
Grinding head of the new STUDER S36 production
cylindrical grinding machine
State-of-the-art grinding technology
for optimum price/performance
An outstanding feature of the new machine is its
large grinding wheel, which has a Ø 610 mm and
initially a maximum width of 125 mm. This makes
the S36 above standard in its category. In addition,
the machine comes with C.O.R.E. OS, the UNITED
GRINDING Group’s smart, cross-brand operating
system – including touch panel and intuitive operation.
Thanks to the uniform C.O.R.E. software
architecture, data exchange between the machines
is easily possible. This is also possible with thirdparty
systems via the integrated umati interface.
This interface also provides access to the UNITED
GRINDING Digital Solutions products directly
at the machine and without the installation of additional
hardware. C.O.R.E. creates the technical
foundation not just for these and other IoT and data
applications, but also for a revolutionary, standard
and simple mode of operation.
The newly developed SmartJet® nozzles for efficient
and automatic coolant supply are fitted as standard.
Thanks to these cooling is now managed by
the machine control. A frequency-controlled pump
and a dynamic pressure measuring unit are used
as central components. These allow to precisely adjust
the volume flow to suit the process – for rough
grinding, fine grinding or finishing. The cooling
medium is fed to the grinding wheel via manifold
and flow-optimized, adjustable nozzles. “This concept
guarantees precise, efficient and reproducible
cooling”, emphasizes Martin Habegger. “We offer
customers the S36 with all of this modern grinding
technology at an excellent price/performance ratio”,
says Habegger.
STUDER S36 production cylindrical grinding machine
further information: www.studer.com
no. 3, August 2022
35

machining center
A breakthrough on superfinishing of high loaded gears
Big cost savings into aerospace production
High loaded gearboxes, such as reduction, propeller
and helicopter gearboxes, are counted as the highest
loaded gearboxes with the highest precision in design,
validation and manufacturing. Many gearboxes
in this application are designed as a planetary gear
system that transmits the torque from the low-pressure
turbine to the propeller, rotor or fan. With this
gearbox design, many benefits such as fuel burn savings,
engine noise reduction and engine operation cost
reduction can be achieved.
Besides stringent design drawing criteria, gear teeth topography
(teeth flanks lay) also plays a very important role
in preventing the highly loaded gears from pitting and
scuffling failures. It calls for perfect gear teeth surface
and can be achieved by the process introduced by OTEC
Präzisionsfinish GmbH (OTEC). The gear teeth surface is not
only perfectly polished, but sharp edges or burrs on the part
are also being removed. With this process one also achieves
different surface requirements (i.e. superfinishing, edge
rounding, deburring etc.) on blades, vanes, disks, blisks,
roots as well as gears.
photo 1
Media size in comparison to the gear geometry
Stream Finishing MachineOTEC was chosen to be a partner
of many well-known Aerospace OEMs and TIER 1s,
because the offered processes have proven that it’s not only
simple, effective and highly productive but also environmentally
friendly, in line with current production requirements.
OTEC’s solution proved to be economical in industrial processes
as well. With less media, compound and water wastage,
along with faster process time, productivity and efficiency
will definitely be improved.
In one particular research, a wet finishing process was conducted
in OTEC’s Stream Finishing (SF) machine. High quality
surface results could be achieved when the correct abrasive
media, specifically chosen according to the different geometry
sizes of the workpieces, was used in conjunction with
the optimum machine parameter settings. With the small
sized media (photo 1) used in the Stream Finishing process,
small and hard to reach could easily be accessed and offering
a very big advantage over the conventional methods.
photo 2
Low process variation
achieved from OTEC’s
Stream Finishing process
With wet finishing,
the water/compound mixture
served to absorb
and rinse away the particles
of debris from
the workpieces and the
abrasive medium. This
ensured that the maximum
efficiency was retained
throughout the
entire processing cycle. OTEC’s special designed finishing
process for highly loaded gears had not only got a positive
impact on the roughness parameter and reduction of teeth
involute curvature waviness, desirable teeth flank topography
and excellence repeatability for teeth involute and teeth lead
could also be achieved.
Initial test pieces of a highly loaded gear were grinded by a
high precision grinding machine to an ISO 1302 grade number
N5 surface roughness. With OTEC’s finishing processes,
a surface roughness between ISO 1302 grade N3 and N2 was
achieved in a short time of only 20 – 30 minutes. Most important
visual grinding lines were also removed from the part.
This high accuracy surface finishing has generated a resistance
against scuffing and pitting which may result in a significant
increase in the lifetime of the gearbox.
Photo 2 shows the calculated variation of material removal
along multiple involutes for the tested workpiece. Compared
to conventional methods, an incredibly low process variation
of only 1 µm was achieved along the involutes with OTEC’s
Stream Finishing process. This can help increase the tolerance
allowanced for the initial grinding process, and scrap
rate in production can also be reduced. Tighter tolerances
could also be applied on the gear manufacturing drawing
and thus reduce the gear weight which is also a key factor in
aviation.
Several well-known OEMs and TIER 1s are already partnering
with OTEC, looking into the process verification
and validation of the Stream Finishing solution, believing to
reach another milestone in aerospace production with this
partnership very soon.
further information: www.otec.de
36 no. 3, August 2022

Highest precision with two options
machining center
At AMB 2022 Kern will present two machines –
both are characterized by the highest precision on the
workpiece, but based on two completely different technologies.
The latest generation of the five-axis machining
center Kern Micro HD and the modern laser
machining center Kern Femto E3.
Producing parts in serial production with a reliable process
and highest accuracies in the µm-range requires machines
like Kern Microtechnik GmbH provides. With the Micro HD
and the Femto E3, Kern Microtechnik is showing visitors two
innovative machining centers in action, which are similar in
terms of color and are characterized by the highest level of
precision but differ significantly in the used technology.
On the Kern Micro HD Kern machines form inserts for filter
housings that are milled and ground in one setting. This
means that the parts are first machined and then brought
to the highest surface quality at individual points using jig
grinding with five-axis cycles. As a result the parts have a
precision of less than 1 µm and surface qualities in the singledigit
nanometer range on various contact surfaces. The usual
manual polishing is no longer necessary.
Also live: the new Kern Femto E3 laser machining center
has proven to be the ideal manufacturing solution for the
The high-precision
five-axis
machining center
Kern Micro HD
production of sintered carbide press dies and similar parts.
The machine uses an ultra-short pulse laser to process hard
materials with the highest dimensional accuracy of +/- 3 µm
without heat input. Since the laser is not subject to wear, there
are no tool costs. With surface qualities of up to Ra = 0.2 µm,
the new Kern technology is highly productive and extremely
stable. Compared to EDM‘ing the time of production can be
cut by 75 %. The Femto E3 can also texture surfaces quickly
and easily on a wide variety of materials.
AMB 2022, hall 7, booth B71
further information: www.kern-microtechnik.com
Reduced space consumption
Multi-machine automation < 1.0 m
Production areas are expensive, especially when
they have to be air-conditioned for high-precision
production applications. Therefore, production areas
should primarily be used for machines. Due to the
growing trend towards Industry 4.0 and automation,
however, production areas for handling workpieces or
tools are increasingly being lost.
The new RCF30 automation from
Röders is extremely space-saving and has a width of < 1.0 m
In order to reduce space consumption caused by automation
in production, Röders is presenting the extremely narrow linear
multi-machine automation RCF30. The width, including
the shelving system, is less than 1.0 m. Nevertheless, a workpiece
weight of up to 30 kg can be handled. A gripper change
enables the handling of different types of pallets and tools.
The stiff construction makes the RCF30 very fast. The RCF30
is delivered to customers in ready-made modules, avoiding
lengthy, expensive installation work. A gradual expansion is
possible at any time. Due to Röders' many years of experience
in multi-machine automation, measuring machines, eroding
machines, etc. can also be integrated.
AMB 2022, hall 7, booth B88
further information: www.roeders.de
no. 3, August 2022
37

components
Robot-assisted separation of screw and plug connections
Automated disassembly of battery systems
written by
Thomas Götz and Andreas Gebhardt,
Fraunhofer Institute for Manufacturing Engineering and Automation IPA
Electromobility plays a decisive role in the design
of sustainable mobility concepts, as it forms the
basis for a sustainable reduction of environmentally
harmful emissions. However, the transformation towards
electromobility presents the German automotive
industry with technical and structural challenges,
which are also associated with economic and social
implications. [1]
The raw materials required for the production of
lithium-ion batteries, such as lithium, cobalt, nickel
or manganese, are proving to be particularly problematic.
Their supply situation is risky due to the monopolistic
market position of some production countries
[2, 3]
and their extraction and production are accompanied
by significant ecological and social problems [4] .
Against this background, a systematic recycling of battery
components is imperative from an ecological, economical
and strategic supply perspective. In view of the expected
shortage of raw materials in the future and the simultaneous
increase in demand, the recovery of technology metals
by means of recycling will play a key role. This applies in particular
to the materials used in electrodes. [5]
Further potentials are provided by both the reprocessing
and reuse of individual battery components and by the reassembly
of still functioning individual parts into functional
modules [6] . However, such a systematic recycling of central
components requires large-scale industrial dismantling
concepts with a high degree of automation [7] .
dismantling
level
battery
pack
battery
module
detachable
connection type
screw connection latching welding/
soldering
• housing
• module contacting
system
• battery management
system
• cooling system
• connections
• module
management system
• connections
• battery modules
• clamping elements
• wiring
• connections
• module housing
• clamping elements
• wiring
• connections
• wiring
• connections
• module housing
table 1
Connection types of battery components [9]
An important component for the fully automated dismantling
of battery systems is the separation of screw and plug connections.
Corresponding processes were investigated within
the framework of the joint project DeMoBat – “Industrial
Disassembly of Battery Modules and E-Motors”, which is the
subject of this article.
Structure and disassembly of battery systems
Due to their high energy density, lithium-ion batteries form
the basis for most modern concepts for powertrain electrification
of all types of vehicles [8] .
This battery technology uses lithium-ion cells that are connected
in series in a module. In addition to the cells, the
module contains other electronic components such as cooling
modules, a cell overvoltage monitor, wiring, connections
to the outside and a module management system. Several
modules and other peripheral components such as clamping
elements, wiring, contacting systems, external connections
and the battery management system are then assembled into
a battery system, which is dimensioned differently depending
[9, 10]
on the required performance data.
The individual components are assembled into the battery
system using various connection technologies, with both detachable
and non-detachable techniques being employed [9] .
Table 1 lists typical connection types of the individual
components.
For battery dismantling, the first recycling concepts for
high-performance batteries of electric vehicles were developed
within the research project
LiBRi - “Lithium-Ion Battery
undetachable
• cell contact system
• wiring
• connections
bonding
• connections
• cooling plates
• connections
Recycling Initiative”. In this context,
guidelines for a recyclingcompatible
battery design were
also derived. Easy dismantling
respectively the use of detachable
connections (e.g. screw connections,
latches) for cells and electronics
were identified as central
prerequisites for a dismantlingfriendly
design. [11]
In the research project Litho-
Rec – “Recycling of Lithium-Ion
Batteries”, the mechanical disassembly
of vehicle batteries in
individual components was investigated
in practice. Due to
38 no. 3, August 2022

components
the expected diversity of battery designs, the disassembly
work was carried out as purely manual activities by skilled
electricians with the aid of standard manual or mechanical
tools. Standard tools such as screwdrivers, spanners, but also
pneumatically or electrically driven screwdrivers were used
for unscrewing screw connections (figure 1a). In the case of
vehicle batteries that were installed on the subfloor and exposed
to moisture, the housing screws could be oxi dised,
so that stuck screws had to be removed destructively using
chisels or angle grinders. Plug connections were opened
manually (figure 1b), whereby manufacturer-spe cific plugs
could usually only be opened with special tools. In case the
connectors could not be opened manually, the cables were
cut with cable cutters. [12]
Since a higher degree of automation in the dismantling of
battery systems makes an important contribution to increasing
the efficiency and cost-effectiveness of the hitherto purely
manual dismantling process, the first tests on the semi-automated
dismantling of battery systems were carried out in the
follow-up project LithiumRec II. A human- machine collaboration
was investigated, in which complex disassembly activities
such as loosening plug connections were carried out
by a human and simple activities by a robot. Among other
things, a robotic end effector was developed for automated
disas sembly of screw connections, based on a cordless drill
for manual handling and equipped with an additional singlefinger
gripper for screw removal. [13]
drilling and milling processes were investigated in detail as
part of the DeMoBat project.
A six-axis KUKA KR600 R2830F articulated robot with a
Siemens SINUMERIK 840D controller and an HSD ES951 L
1612 S high-frequency spindle used to carry out the experiments.
To ensure the safety of destructive dismantling, technical
requirements were therefore placed on the machining
process. For example, the use of coolants and lubricants must
be avoided, as moisture inside the battery can lead to short
circuits. Metal chips must also be collected and removed by
an appropriate extraction system, as they can lead to short
circuits or other damage inside the battery.
Separation of screw connections
The aim of the first series of tests was to investigate robotassisted
drilling and milling for the destructive separation
of screw connections.
For the machining tests, a simplified test carrier was
developed, consisting of an aluminium tube with attached
aluminium plate, both connected to each other via a steel
ring with the aid of galvanised DIN 7985 pan-head screws
with TORX drive of size M6 x 12 mm. The test carrier forms
the components and materials of the battery housing type
PHEV PB320 from Accumotive GmbH & Co.KG which was
considered in the DeMoBat project. It was clamped onto the
machining table by means of a three-jaw chuck.
Within the scope of the test series concerning the separation
of screw connections by means of robot-assisted drilling
methods, the process variant of solid drilling was examined
more closely, using solid carbide twist drills of the type DIN
6537K of the company Gühring KG.
figure 1a
Manual disassembly of screw connections [14]
figure 1b
Manual disassembly of plug connections [15]
Design and execution of experiments
In order to enable automated disassembly of corroded or
stuck housing screws and plug connections beyond the current
state of the art, strategies for the destructive separation
of screw and plug connections by means of robot-assisted
As a cutting strategy, the reaming of the thread passage
was considered first. A twist drill with a diameter of 6.5 mm
was used to drill directly to the target depth at a cutting
speed of v c = 80 m/min and a feed rate of f = 0.15 mm (“oneshot
drilling” process).
Since the complete screw head was stuck on the main
cutting edge of the drilling tool during the drilling of the
threaded passage (figure 2a) and thus the separation of
a second screw connection with this tool was prevented,
the drilling of the complete screw head (screw head diameter
12 mm) offered itself as a second strategy, which was
also investigated as a one-shot drilling process using a twist
drill with a diameter of 12.5 mm. Here, a cutting speed of
v c = 160 m/min and a feed rate of f = 0.25 mm were selected.
When using this strategy, a screw head residue with continuously
running and coherent chip elements settled on the
drilling tool in the form of flow chips (figure 2b).
For this reason, the alternative strategy of reaming the
screw head as a drilling cycle with chip breaking (“peck
drilling” process) was chosen. In this drilling cycle, drilling
was carried out successively to the target depth, with a feed
interruption after every 0.5 mm advance in z-direction followed
by a short retraction in the opposite direction. This
no. 3, August 2022
39

components
figure 2a
Screw head on
drilling tool Ø 6.5 mm
figure 2b
Screw head residue with flow chip on
drilling tool Ø 12.5 mm
figure 2c
Screw head residue on
drilling tool Ø 12.5 mm
made it possible to produce fracture chips suitable for the
use of an extraction system. However, in a first test run it
could be observed that in about every fifth screwed connection
drilled out, a screw head residue in the form of a narrow
ring got caught on the main cutting edge of the drilling tool
(figure 2c). This screw head residue was then carried along
on the main cutting edge to the next screw head to be drilled
out. This not only prevented a process-reliable separation
of the following screw connection, but also resulted in the
tool life limit being reached prematurely after only 32 screw
connections.
Since it was not possible to reliably separate the screw
connections and remove the chips in the drilling processes
considered, the separation of screw connections using robot-assisted
milling processes was investigated in further test
series. Here, circular milling was used as milling strategy.
With this type of movement, the milling tool plunges into
the screw head with a circular feed movement around its
longitudinal axis, which enables the use of a tool-enclosing
extraction system for chip collection.
Four-edged solid carbide corner radius milling cutters
with a diameter of 8 mm and a corner radius of 1 mm of the
type NVV 0334 56 081 of the company Pokolm Frästechnik
GmbH & Co. KG were used, whereby a speed of n = 4777 min -1 ,
a feed rate of v f = 1433 mm/min, a cutting speed of v c = 120 m/
min, a helix diameter of D h = 5 mm (drilling diameter
D B = 13 mm) and an axial cutting depth per helix revolution
of a* p = 0.35 mm were selected.
In the milling tests it could be observed that the milling
strategy allowed a safe separation of the screw connections
(figure 3, a and b). An initial wear test with three test tools
also revealed that under the given conditions, around 200
screw connections could be reliably separated with one milling
tool until the wear limit was reached.
An interchangeable unit-type extraction system was developed
to collect the accruing chips (figure 4, a and b). Its
functionality was verified in the circular milling process application.
The chips were collected via an extraction hood
that could be adjusted in z-direction and to which a vacuum
cleaner was connected. A brush ring was mounted around
the edge of the hood to enclose the milling tool. The brush
ring allowed the best possible sealing of the cutting point and
avoiding collisions with the battery housing at the same time.
The brush ring slowed down the ejected chips during circular
milling so that they could be picked up by the air flow of the
vacuum cleaner to be transported away.
figure 3, a and b
Separation of screw connections in the circular milling process
40 no. 3, August 2022

components
interchangeable unit
with HSK 63F mount
clamping chuck
connection for
vacuum cleaner
extraction hood
brush ring
cutting tool
figure 4a
Construction of the extraction system
figure 4b
Extraction system inserted in the high-frequency spindle
Disconnecting plug connections
Within a second series of tests, the suitability of robot-assisted
drilling and milling for the destructive separation of
plug connections was investigated. First, four different plug
connections were selected on the basis of a plug analysis of
the PHEV PB320 battery (table 2). Special care was taken to
ensure that the selection covered both the largest and smallest
connector in terms of dimensions, the entire material mix
of all built-in connectors and all different designs.
A modular clamping device was developed for the machining
tests, which reproduces the geometric shapes of the
respective mating connectors in an exchangeable bar. For
clamping, the connectors are clicked into their mating connectors,
which are then clamped in the clamping device with
the help of screws. The cables crimped with the plugs are
fixed by cable tensioning bars.
Within the scope of the cutting tests, a double-edged
HSS long-hole cutter, type 3453, with center cut and special
drill face of the company Gühring KG, with a diameter of
10 mm was used. The cutting strategies considered were
circumferential milling in synchronisation, plunging (for
plugs whose di mensions are smaller than the cutter diameter)
and a combination of plunging and circumferential milling
(for plugs whose dimensions are larger than the cutter diameter),
where by the process parameters were adapted for each
plug type (table 3).
In the machining tests (figure 5), the TRU Components
pre-fab braid connectors in particular presented a challenge.
In some cases, for example, the flexible crimp contacts could
not be completely separated by the milling cutter during the
plunging strategy. A remedy was provided by circumferential
milling, whereby care had to be taken to ensure that the
TRU Components
pre-fab braid
Cimco
flat connector
AMP
Super Seal
Molex
Micro-Fit
table 2
Selected plug connections
peripheral
milling
plunging
plunging and
peripheral milling
TRU Components
pre-fab braid
v c = 80
m/min
n = 2.548 min -1
v f = 382
mm/min
n = 2.548 min -1
v f = 305
mm/min
v c = 120
Cimco
flat connector
m/min
n = 3.822 min -1
v f = 765
mm/min
n = 2.548 min -1
v f = 485
– –
mm/min
v c = 100
AMP
Super Seal
m/min
n = 3.185 min -1
v f = 446
v c = 100
mm/min
v c = 100
Molex
Micro-Fit
m/min
n = 3.185 min -1
v f = 446
– –
m/min
n = 3.185 min -1
v f = 318
mm/min
v c = 80
mm/min
m/min
n = 2.548 min -1
v f = 306
mm/min
table 3
Choice of process parameters
no. 3, August 2022
41

components
cutter was guided as closely as possible to the mating
connector for reliable separation.
In comparison, the Cimco flat plugs which displayed
a higher stability due to their high metallic
content, did not pose a challenge. For this type of connector,
both plunging and peripheral milling proved
to be suitable cutting strategies. The retaining mating
connector was either pushed away or cut by the
milling tool.
The AMP Super Seal as well as the Molex Micro-
Fit connectors could also be separated by means
of circumferential milling and a combination of a
plunging movement and subsequent circumferential
milling. When using the combination, it was observed
that the connector broke out of the holding
mating connector in some cases.
As a result of the investigations, it can be stated that a reliable
separation of plug connections is basically possible by using cutting
processes. However, the contamination caused by the chips proves
disadvantagous. In the case of connectors with a high metal con tent,
the chips can lead to short circuits in the battery, which makes it necessary
to collect them. In the battery under investigation, however, the
required accessibility for this is not given for every plug connection.
For this reason, the disconnection of cables close to the connector
was investigated as an alternative. The cutting tool used was a
pneumatic cutter, type AR-50, of the company Artur Martin e.K.,
which uses the knife cutting
method to cut the
cables with the help of
a wedge-shaped blade
that is moved onto a flat
surface. A cable cutting
test rig (figure 6, a
and b) was developed for
the tests, allowing a defined
number of cuts to
cutter
be made with the pneu -
matic cutter.
cut removal
figure 5a
TRU Components pre-fab braid connector –
disconnection tests
figure 6a
Construction of the
cable separation test rig
cable feed
cable drum
housing
figure 5b
Cimco flat connector – disconnection tests
figure 6b
Cable separation
test rig in use
figure 5c
AMP Super Seal – disconnection tests
24 cables with a cross-section of 0.34 mm 2
were bundled as test cables, and sheathed
with the help of a fabric tape (figure 7a), which
corresponds to the thickest cable bundle installed
in the battery. The tests proved the
suitability of the pneumatic cutters for cutting
cables. Even after 2,500 cuts, the cutting
edge showed no appreciable wear (figure 7b
and c), while the cables were cut reliably.
figure 7a
Separated cables
figure 5d
Molex Micro-Fit – disconnection tests
figure 7b and c
Cutting edge after 0 cuts
Cutting edge after 2,500 cuts
42 no. 3, August 2022

components
Conclusion and outlook
The recycling of battery systems will play an important role
for sustainable electromobility in the future, but its economic
efficiency requires a high degree of automation in the
dismantling process. For this purpose, robot-assisted drilling
and milling strategies were investigated in order to destructively
loosen screw and plug connections. In addition, the use
of pneumatic cutters for separating cables was investigated.
For separating screw connections, circular milling proved
to be a process-reliable method in compliance with all technical
and economic requirements. An extraction system for
circular milling was presented to collect the chips produced.
Cutting processes also proved to be fundamentally suitable
for separating plug connections. However, in some cases
the necessary accessibility to the plugs in the battery is not
given. As an alternative the cutting of cables close to the
plugs by means of pneumatic cutters was investigated.
Future research includes the cryogenic cooling of the cutting
process to avoid flying sparks and monitoring the extraction
process of the chips. A robot-guided cable cutting
unit (consisting of a gripper and pneumatic cutters) will also
be developed and tested.
Acknowledgements
The project DeMoBat – “Industrial dismantling of battery
modules and e-motors to secure economically strategic
raw materials for e-mobility”, on which the present investigations
are based, is funded by the Baden-Württemberg
Ministry for the Environment, Climate and Energy Management
(UM BW) and supervised by the Karlsruhe Project
Management Agency (PTKA). The authors would like to
thank the UM BW for the funding granted as well as the
PTKA and all project partners involved for their support.
Special thanks go to Andre Mildner, Konrad Kollotzek and
Lukas Zimmermann for the support provided as part of
their respective thesises.
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Luhn, M (2021)
Transformation zur Elektromobilität: eine
empirische Analyse zur Identifizierung der relevanten
Einflussfaktoren und Modellierung der Transformationsfähigkeit
von Automobilzulieferern in Deutschland
DuEPublico: Duisburg-Essen Publications online,
University of Duisburg-Essen, Germany
[2]
Reuter, B.; Hendrich, A. (2020)
Verfügbarkeit kritischer Rohstoffe für Elektrofahrzeuge
ATZ – Automobiltechnische Zeitschrift 122/4, page 54 - 57
[3]
Backhaus, R. (2021)
Batterierohstoffe – Woher und wohin?
ATZ – Automobiltechnische Zeitschrift 123/9, page 8 - 13
[4]
Köllner, C. (2021)
Öko-Probleme bei den Batterie-Rohstoffen
Lithium und Graphit
internet: https://www.springerprofessional.de/batterie/
ressourceneinsatz/oeko-probleme-bei-den-batterierohstoffen-lithium-und-graphit/18790148
[5]
Berger, C. (2021)
Batterie-Recycling ist entscheidendes Zukunftsthema
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elektrofahrzeuge/batterie-recycling-ist-entscheidendeszukunftsthema/19241690
[6]
Buchert, M.; Sutter, J. (2020)
Stand und Perspektiven des Recyclings von
Lithium-IonenBatterien aus der Elektromobilität
Synthesepapier erstellt im Rahmen des vom Bundesministerium
für Umwelt, Naturschutz und nukleare Sicherheit
geförderten Verbundvorhabens MERCATOR “Material Effizientes
Recycling für die Circular Economy von Automobilspeichern
durch Technologie ohne Reststoffe”, Darmstadt
[7]
Köllner, C. (2019)
Ist Second Life besser als direktes Akku-Recycling?
internet: https://www.springerprofessional.de/batterie/
recycling/ist-second-life-besser-als-direktes-akkurecycling-/16512034
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Tschöke, H. (2015)
Die Elektrifizierung des Antriebsstrangs
Wiesbaden: Springer Fachmedien Wiesbaden
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Weyrich, M.; Natkunarajah, N. (2013)
Konzeption einer automatischen Demontageanlage
für Lithium-Ionen-Batterien
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Kampker, A.; Heimes, H. H.; Deutskens, C. et al. (2015)
Montageprozess eines Batteriepacks
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Treffer, F. (2011)
Abschlussbericht zum Verbundvorhaben Entwicklung
eines realisierbaren Recyclingkonzeptes für die
Hochleistungsbatterien zukünftiger Elektrofahrzeuge
Lithium-Ionen Batterierecycling Initiative – LiBRi, im
Rahmen des FuE-Programms “Förderung von Forschung
und Entwicklung im Bereich der Elektromobilität”
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Recycling von Lithium-Ionen-Batterien
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Schaal, S. (access August 2, 2022)
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Pilot-Recyclinganlage in Betrieb
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further information: www.ipa.fraunhofer.de
no. 3, August 2022
43

components
Analyzing and optimizing cleaning processes
Cleaning processes often offer considerable potential
for improvement when it comes to making parts
cleaning operations more reliable, economical and sustainable.
The first step is to make a systematic process analysis that
also takes a close look at upstream and downstream production
steps. To ensure the quality of subsequent process steps,
avoid rejects and guarantee the functionality of the end product,
consistent parts cleanliness is an essential quality criterion.
Ever-stricter or even modified cleanliness specifications
must be met. In addition demands on the speed, costeffectiveness
and sustainability of the cleaning process are
constantly rising. However, how well, fast and efficiently the
cleaning work is carried out depends not only on the equipment,
the process technology and the medium used, but also
on factors relating to the cleaning process itself.
Systematic process analysis –
looking at the big picture
So what do you do if suddenly stained parts come out of the
system, if specifications for particulate or thin-film cleanliness
are no longer met, the cleaned parts arrive corroded
at the customer’s, or cleaning is too slow/too cost-intensive?
In these and other cases a systematic process analysis
carried out by – for example – the Ecoclean Academy at
Ecoclean GmbH can pinpoint the cause of the problems. The
cleaning experts not only focus on the actual cleaning process
and equipment, but also assess the overall manufacturing
environment. The smallest change to the part, part spectrum
or material, type of contamination, or modifications
to upstream or downstream processes is enough to seriously
impair cleaning results.
Stains and thin-film residues on parts
According to the cleaning experts a poor cleaning result or
one that does not meet new higher requirements is a “classic”
reason for carrying out a process analysis. The first step is to
identify the exact problem – are thin-film cleanliness specifications
not being fulfilled or are there stains on the parts?
If staining is the problem, one of the questions to be asked
is whether the quantity and composition of the contaminants
(processing media and other substances) have changed or
whether the constituents and concentration of the cleaning
medium are still appropriate. Other factors, such as rinsing
water quality, bath treatment, process technology and process
sequence, as well as the drying step, are also closely examined.
These are further influencing variables playing a role if
thin-film cleanliness results are unsatisfactory.
Inability to meet particulate
cleanliness requirements
If the cleanliness analysis after the cleaning cycle shows that
too many or too large particles are still adhering to the parts,
Regular inspection and maintenance of machine components
such as filters are essential factors when it comes to meeting
particulate cleanliness requirements in a consistent and
economical manner
this may also be due to the cleaning program and process
sequence used. Possible causes include residual particles in
the working chamber or on the part carriers, an unsuitable
filtration system or a clogged filter. Sometimes it is the wrong
choice of cleaning containers, such as crates made of perforated
galvanized sheet metal, which hinders the efficient and
reliable detachment and removal of the particles. This type of
crate blocks ultrasonic waves and prevents them from developing
their full effect on the wash load. Likewise, the spray
pressure does not reach the inside of the perforated crates.
Compared to baskets made of round wire, a further problem
is that the cleaning medium does not drip off these crates
as effectively. This may result in the unwanted transfer of
contaminants and/or cleaning chemicals. In any case much
longer and thus more energy-intensive drying processes are
required.
A further cause of a failed cleanliness inspection is often
burrs that are still attached to the parts, which detach when
the parts are handled during the residual contamination
check and then show up on the particle filter. If these particles
are examined under a microscope, it can be determined
whether they are chips or burrs. If the latter is the case, upstream
processes must be evaluated to find out where the
burrs occur and how their formation can be avoided. Particulate
cleanliness can also be impaired by magnetism that is
“bought in” with raw materials or arises during the manufacturing
process. Magnetism binds chips to the parts and hinders
or prevents their removal during the cleaning process.
44 no. 3, August 2022

components
In many cases, retrofitting/upgrading the cleaning system with process technology, for example with ultrasonics,
makes it possible to consistently achieve the required results and to shorten cleaning times
Handling parts after cleaning
When the parts come out of the machine with the required
level of cleanliness the cleaning process is not over yet. To
prevent recontamination or corrosion, which can occur even
with preserved or passivated parts, it is important to look at
the handling of the parts after the cleaning step. The following
questions need to be answered: Where, how and for how
long are the parts stored? How are they transported to the
next processing step? What kind of packaging is required?
Additionnally high cleanliness requirements for processes often
need to be performed in a clean environment or cleanroom,
such as internal transport, assembly or packaging.
Updating the cleaning process
Besides cleaning problems, modified cleaning programs can
be a further reason for carrying out a process analysis. The
aim is generally to shorten process times or enhance the
cleaning result. The analysis always starts by documenting
the actual state, including verifying the process parameters,
process sequence and process times. Based on the analysis results,
potential for improvement can be identified and appropriate
measures can be defined. These may include modernizing
the system, such as by retrofitting or upgrading ultrasonic
equipment.
Qualified personnel
It is essential that the parts cleaning staff are involved in the
process analysis and optimization measures. Raising staff
awareness about cleanliness, as well as about the capabili-
Thanks to
systematic
process analysis
sources of
error and
potential for
improvement
can quickly be
identified
ties of the cleaning technology and the impact of parameter
settings on the cleaning result, is a key factor. If there is
a change of personnel, it is also important that knowledge
of how the cleaning system works and how, for example,
bath treatment measures or regular maintenance work
on the cleaning system are carried out is passed on. Otherwise,
problems that had been eliminated in the past may
occur again. Investing in the training and continuing
education of cleaning staff is therefore a cornerstone in or -
der to achieve reliable cleanliness requirements in an economical
and sustainable manner. The Ecoclean Academy
therefore also combines process analyses with classic training
courses.
further information: www.ecoclean-group.net
no. 3, August 2022
45

components
100 % tool management
New releases available
Beyond a big face-lift, TDM Release
2023 allows users to synchronize their
databases and achieve optimized range
calculation easier. In TDM Global Line,
the operational applications in the tool
room and the handling of the tool lifecycle
has also been developed further.
Smaller machining companies which
are looking for a simple, cost-effective
entry-level solution can find out about
the cloud-based TDM Cloud Essentials
software line.
TDM Global Line 2023 offers, among other things,
further developments in the Tool Room
TDM 2023 with a big face-lift facilitates the synchronization of databases
TDM Systems is presenting their products and services under this
headline at the AMB 2022. In addition to the new main releases from
TDM Global Line and TDM, the provider of tool management solutions
is presenting their new services for processing tool data and demonstrating
the opportunities and benefits of connecting to machine tools.
“Companies that do not digitalize lose their competitiveness,” states the CEO of
TDM Systems, Jean-Paul Seuren, with certainty. The company has offered software
solutions for the efficient management of tool data and tools for over 30
years. “The core competence of TDM Systems is offering machining companies
a highly integrable solution. This supports the entire process chain for the chipmaking
production and ensures that the tools always remain available.”
New data services for
users and tool manufacturers
TDM Systems now offers new data
services for both users and tool manufacturers.
“We have a dedicated data
team who has excellent expertise and
takes on the task of data creation for
customers,” explains Seuren. “Furthermore
we also offer tool manufacturers
the user-optimized digitalization of
their data catalogs."
Data transfer to the machine
And there is something else that will
excite visitors at the TDM booth,
according to Seuren: “We will demonstrate
how the machine down times in
production can be minimized.” Users
can use different communication options
with the production machines to
implement an automated transfer of
tool and order data directly to the machine
control system. This means that
the required tool data can be transferred
without any errors and, by monitoring
the tool life, tools can be retrofitted
in a timely manner.
TDM tool circulation
at DMG Mori
Together with the machine tool manufacturer
DMG Mori, TDM Systems is
also presenting a live showcase with
integrated tool circulation. This also
includes partner systems, such as
Siemens NX, Esprit, Vericut and Haimer
presetting systems.
AMB 2022, hall 2, booth B43
information: www.tdmsystems.com
46 no. 3, August 2022

components
Expanding the field of view in micromachining
Aerotech, the specialist for motion control and positioning
systems, will be exhibiting at Micronora 2022
in Besançon September 27 - 30, hall C booth 306. The
innovative IFOV function for expanding the field of
view during laser scanning will be demonstrated, as
well as the latest features of the Automation1 control
platform.
Micronora is one of Europe’s leading events for microtechnology,
micronanotechnology and precision manufacturing.
This year the fair will be also held “hybrid” for the first
time: on the digital platform “e.micronora”, both real and
virtual visits can be planned, appointments and participation
in accompanying specialist conferences and lectures
be made. “For Aerotech Micronora, as a globally renowned
niche trade fair, is an excellent address to demonstrate our indepth
know-how in microproduction and nanopositioning”,
confirms Simon Smith, European director of Aerotech. “With
our focus topics laser and measurement technology as well as
additive manufacturing support around high-precision positioning
systems in the nanometre range, we find the right
trade audience at Micronora.”
Multi-scanner systems enable complex, large-area and highly
dynamic laser processing between several axes
Laser scanning without stitching
Micronora shows micro actuators, micro sensors and micro
dispays. To improve structural accuracy error-free in “traditional”
stitching, for example, Aerotech’s proven Infinite
Field of View (IFOV) feature is a unique and industry-leading
solution for synchronising linear or rotary servo axes with laser
scanners. IFOV significantly improves throughput, eliminates
seam errors and part quality issues caused by overlapping
and mismatched laser processing. By combining the
highly dynamic capabilities of galvo scanners with the travel
range of servo stages, parts significantly larger than the traditional
field of view of a scanner can be machined continuously
without having to join individual work areas. One example
of this is the production of OLED displays. A big challenge is
cutting out the individual displays from a much larger substrate.
Laser cutting has proven itself for this process step of
micromachining. Multi-scanner systems with IFOV controllers
from Aerotech enable complex, large-area and highly dynamic
laser processing between multiple axes and field-ofview
expansion without the familiar stitching.
further information: www.aerotech.com
Reliable cable guiding on industrial robots
By using the ROBOTRAX cable carrier system in
combination with the innovative PBU pull back unit
from TSUBAKI KABELSCHLEPP, automation expert
KEBA Industrial Automation was able to set up a realistic
technology demonstrator. Reliable cable guiding
was a key element of success.
The international automation expert for machine-integrated
robots, KEBA Industrial Automation, uses its latest demonstrator
to highlight the opportunities of creating a digital
twin of an industrial robot. To illustrate the corresponding
applications, an industrial robot with a versatile tool simulator
was set up. Just as in practical application, a multicore cable
had to move along with this tool simulator, reliably and
safely guided in the robot work envelope even at the highest
travel speeds. TSUBAKI KABELSCHLEPP provided support
with the ROBOTRAX cable carrier, which is in three dimensions
flexible and was optimized for use on industrial robots.
With the PBU pull back unit reliable cable guiding in different
robot positions at high speeds was achieved. The Austrian
distributor for TSUBAKI KABELSCHLEPP provided support
for the practical optimization.
“The cable carrier system impressed us with its easy
installation and versatile fastening options,” explains
Michael Garstenauer, product manager robotics at KEBA. “In
combination with the pull back unit, reliable pretension is
ensured along the complete demonstration paths.” The
dreaded knocking of the energy chain against the robot is
prevented even at the highest speeds while retaining full freedom
of movement. The result is a thoroughly reliable overall
solution that is suitable for long-term use.
further information: www.kabelschlepp.de
no. 3, August 2022
47

components
Efficient automation with robotics,
software and storage system
The system manufacturer KELCH GmbH will be
showcasing the next Industry 4.0-compliant development
stage at this year’s AMB: an efficient automation
concept for machining companies. The total modular
concept is a joint offering with Bachmann Engineering
AG, experts in turnkey robotic cells and automation
solutions, and MySolutions AG, the all-in-one provider
for smart factory automation.
Live presentations will be held showing the entire tool cycle
with the KELCH KENOVA set line V3 and V9 tool presetters
and robotic assistance in a modern smart factory. Collaboratively,
the partners will be supplying complete solutions
worldwide to fully integrate third-party systems on a hardware
and software level.
Efficient automation, flexibly tailored to customers’ needs,
is the aim of the total concept being presented at the AMB.
The concept can also be applied to existing machines and,
being modular, can be introduced into customers’ companies
in small steps, depending on their budget and situation.
“KELCH Industrial Line and Premium Line tool presetters
can be fully integrated into the hardware and software
of automation processes. We will be showcasing this with the
example of a V3 and a V9-S model at the trade fair,” reports
Viktor Grauer, deputy managing director and head of product
and innovation management at KELCH. Automation options
range from tool cleaning, shrinking, assembly to specification
dimensions, balancing and measuring to storage. The
available safety features provide for continuous monitoring
of all processes: from automatic detection of the spindle insert
during automatic change, control of all critical statuses
and media (air, electricity, temperature etc.) to remote monitoring
by IoT. Extended automation is provided for by the
integration of solutions supplied by the cooperation partners
MySolutions and Bachmann Engineering, who along with
KELCH will have their own consultants at AMB.
Optimised use of resources
“As MySolutions AG has been the exclusive sales partner for
KELCH products in Switzerland since 2020, we will be showcasing
our seamless integration with KELCH KENOVA tool
presetters at AMB – including our 2D.ID identification solution.
Our innovative ‘THE BOX’ storage system can also be
integrated, along with our mobile and stationary MyXPert
software products,” explains Paul Gossens, managing director
of MySolutions AG. Visitors of AMB will also learn how
the MyXPert production manager can assist work scheduling
personnel to technically and visually merge all administrative
data and information (including orders/workflows, resources,
NC programs, tool correction data, tools, test and
measuring equipment). This also applies to data from existing
third-party systems, such as ERP/PPS, MES, PLM etc.
THE BOX, the innovative MySolutions storage system
optimises the use of floor space in the warehouse
In conjunction with the MyXPert terminal, a versatile and
modular shop floor management system, product personnel
will receive all production-relevant information on all operating
resources (products, tools, equipment, measuring/
test equipment etc.) on a central user interface directly at the
machine. Seamless integration to external systems (such
as CNC machines, manual and automated storage systems
etc.) is possible using the MyXPert framework, regardless of
whether data and information is merely to be visualised or
reported directly back to external third-party systems. The
result: optimised use of all resources in the production process,
including tool set-up and tool preparation. The modular
MySolutions automated warehouse management concept
provides a valuable addition to automated production:
48 no. 3, August 2022

components
Controller tool presetting including robot from a tablet:
this is now possible with the KENOVA set line V3 CNC and
V956-S in conjunction with the MySolutions MyXPert
tool manager
Automated equipping and changing of tools on KELCH tool
presetters: shown here with a UR10e robot including gripper
on the Bachmann Movable Base
the innovative vertical storage system, known as THE BOX,
is designed for the weight-independent storage of small and
mid-sized products, and optimises the use of floor space in
the storage area. The concept can be extended vertically and
hori zontally any time through horizontally and vertically
stackable elements. Unlike conventional cabinet and drawer
systems, THE BOX enables products to be removed at an
ergonomic height throughout.
Mobile platform:
Bachmann Movable Base with collaborative robot
Bachmann Engineering AG, another KELCH cooperation
partner, will be presenting an additional automation system
at the KELCH booth on AMB, which is specifically designed
for mid-sized to larger companies with their own in-house
CNC machining capability.
The base is formed by the Bachmann Movable Base BMB,
a mobile platform specifically for collaborative robots, which
are flexibly equipped and can be moved to wherever they are
needed. Each platform is equipped with a UR10e robot including
gripper for tool holders positioned directly downstream
of the KENOVA set line V3 or V9 tool presetter to
equip and change tools on the KELCH tool presetters. Live
presentations at the booth will be demonstrating its use
in tool measurement and tool presetting together with the
automated KELCH tool presetters. The system can also be
used in smaller production units, as the Bachmann Moving
Device with a footprint of less then 0.5 m 2 can be simply and
quickly assigned to any production and assembly process. It
includes interfaces to UR3/UR5 and UR10 robots, with other
robots also being possible as required.“The Movable Base and
corresponding robots open up a wide range of uses to companies.
For instance, the automation system might be equipping
a CNC machine during the day, and still preparing the
tools for the next day in the evening,” underlines Marc Strub,
managing director of Bachmann Engineering AG.
Automated complete tool measurement
The entire tool presetting process including robots can be
controlled from a tablet and with all common operating
systems by combining the KENOVA set line V3 CNC and
V956-S with the MySolutions MyXPert tool manager. The
Bachmann Engineering AG UR10e cobot supports the tool
measurement process through automatic loading and unloading
processes – either controlled by a tablet or by visual
detection. The 2D.ID code is scanned and the measuring
specification is transmitted to the system. The measuring
results achieved are saved and the tracking data is
monitored by the MyXPert Tool Manager. “The automated
production solutions showcased on the KELCH stand
at the AMB make the use of individual hardware and software
systems more efficient, but can also help to com -
pen sate for personnel shortages,” continues KELCH manager
Viktor Grauer.
AMB 2022, hall 1, booth F70
further information: www.kelch.de
no. 3, August 2022
49

fairs in alphabetical order
AMB Stuttgart, Germany
(September 13-17, 2022)
bauma Shanghai, China
(November 22-25, 2022)
CIMT Beijing, China
(April 10-15, 2023)
DEBURRING Karlsruhe, Germany
EXPO (October 10-12, 2023)
EMO Hanover, Germany
(September 18-23, 2023)
EPHJ Geneva, Switzerland
(June 6-9, 2023)
FEIMEC São Paulo, Brazil
(May 9-13, 2023)
GrindingHub Stuttgart, Germany
(May 14-17, 2024)
GrindTec Leipzig, Germany
(March 7-10, 2023)
Hannover fair Hanover, Germany
(April 17-21, 2023)
IMT Brno, Czech Republic
(October 3-7, 2022)
IMTS Chicago, USA
(September 12-17, 2022)
JIMTOF Tokyo, Japan
(November 8-13, 2022)
LIGNA Hanover, Germany
(May 15-19, 2023)
MACH-TECH and Budapest, Hungary
INDUSTRY DAYS (May 16-19, 2023)
METALEX Bangkok, Thailand
(November 16-19, 2022)
MOULDING Stuttgart, Germany
EXPO (June 13-16, 2023)
MSV Brno, Czech Republic
(October 3-7, 2022)
SIAMS Moutier, Switzerland
(April 16-19, 2024)
sps Nuremberg, Germany
sps on air digital (November 8-10, 2022)
TIMTOS Taipei, Taiwan
(March 6-11, 2023)
current status
2022
2022
2023
2023
2023
2023
2023
2024
2023
2023
2022
2022
2022
2023
2023
2022
2023
2022
2024
2022
2023
trade fair dates as by beginning of August 2022; we are not responsible for reliability of these dates
50 no. 3, August 2022

impressum
ISSN 2628-5444
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editorial
Aerotech, Inc. .......................47
AMB Messe Stuttgart. ................25
ANCA Pty Ltd. ......................10
CHIRON Group .....................32
Coborn Engineering Co Ltd ...........34
Ecoclean GmbH .................... 44
EMUGE-Werk GmbH & Co. KG .......16
Fraunhofer Institute for
Manufacturing Engineerig and
Automation IPA ...................38
Fritz Studer AG ................. 28, 35
Gleason Corporation ................19
Haas Schleifmaschinen GmbH ........30
Hartmetall-Werkzeugfabrik
Paul Horn GmbH ............ 6, 13, 15
KELCH GmbH ..................... 48
Kern Microtechnik GmbH ............37
advertising index
company finder
Lach Diamant
Jakob Lach GmbH & Co. KG ..14 , 18, 20
Leuco Ledermann GmbH & Co. KG ....17
LMT Tools Group ...................19
NEURA Robotics ....................19
OTEC Präzisionsfinish GmbH ........36
Platinum Tooling Technologies, Inc. ...14
Röders GmbH .......................37
Scansonic MI GmbH .................23
TDM Systems GmbH ............... 46
TIMTOS .......................... 24
TITANS of CNC ................... 24
Tschudin AG .................... 23, 33
TSUBAKI KABELSCHLEPP .........47
UNITED GRINDING Group .........22
Yamawa Europe Spa .................12
ZECHA ........................ 16, 26
CERATIZIT Deutschland GmbH ...................................... back cover
Haas Schleifmaschinen GmbH ...........................................page. 9
Jimmore Intenational Corporation .......................................page.11
Lach Diamant Jakob Lach GmbH & Co. KG .......................inside front cover
Landesmesse Stuttgart GmbH ............................................page 15
Hartmetall-Werkzeugfabrik Paul Horn GmbH ..........................front cover
Reishauer AG ..........................................................page 5
ZECHA Hartmetall-Werkzeugfabrik ......................................page 13
no. 3, August 2022
51

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TEAM CUTTING TOOLS
CERATIZIT is a high-tech engineering
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Tooling the Future
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