hpt 2022 #4

ISSN 2628-5444 

high precision tooling 

Machine Tools, PCD, PVD, CVD, CBN, Hard Metal 2022 – 4 

■ Productivity and sustainability are not mutually exclusive ■ Precision tool cutting edge cooling ■ 

■ Filtration in machining processes ■ Retrofit unit for cryogenic process cooling ■ Automation of tomorrow ■

Accurate cutting edge 

cooling with the 

MaxiLock – S-DC 

DirectCooling (DC) system by CERATIZIT – 

now for turning holders! 

Three nozzles for the 

ultimate cooling effect 

- improved process security 

- higher service life 

Find out more at: 

cutting.tools/gb/en/direct-cooling 

TEAM CUTTING TOOLS 

CERATIZIT is a high-tech engineering 

group specialising in cutting tools and 

hard material solutions. 

Tooling the Future 

www.ceratizit.com

E-Mail puk@harnisch.com 

Internet www.harnisch.com 

Dr. Harnisch Verlags GmbH 

Eschenstraße 25 

90441 Nürnberg 

Telefon +49 (0) 911 2018-0 

Fax +49 (0) 911 2018-100 

E-Mail puk@harnisch.com 

Internet www.harnisch.com 

EINFLUTIGE SCHRAUBENSPINDELPUMPE 

Materials: carbon steel, stainless steel, 

MIT MAGNETKUPPLUNG duplex stainless steel; others on request 

Differenzdruck-Begrenzungsventil 

MEHR INFOS 

www.klaus-union.com 

SINGLE VOLUTE TWIN SCREW PUMP 

WITH MAGNET DRIVE 

Modulares, axial geteiltes Gehäuse 

Werkstoffe: Kohlenstoffstahl, MORE INFO Edelstahl, 

Duplex Edelstahl; weitere auf Anfrage 

Dr. Harnisch Verlags GmbH 

Eschenstraße 25 

90441 Nuremberg, Germany 

Phone + 49 (0) 911 2018-0 

Fax + 49 (0) 911 2018-100 

www.klaus-union.com 

Axial split modular casing 

Differential pressure limiting valve 

Spalttopfausführungen: 

E metallisch / nicht-metallisch 

E einschalig / doppelschalig 

Containment shell executions: 

E metallic / non-metallic 

E single / double shell 

Wasser Abwasser Umwelttechnik 

Energie Öl Gas Wasserstoff 

Fahrzeugbau Schiffbau Schwerindustrie 

Chemie Pharma Biotechnik 

Lebensmittel- und Getränkeindustrie 

Water Wastewater Environmental Technology 

Energy Oil Gas Hydrogen 

Automotive Shipbuilding Heavy Industry 

Chemistry Pharmaceutics Biotechnology 

Food and Beverage Industry 

WANGEN_PuK_Titelseite_216x182.indd 1 24.01.2022 15:23:40 

Independent magazine for Pumps, Compressors and Process Components 

WANGEN_PuK_Titelseite_216x182.indd 1 24.01.2022 15:24:33 

Unabhängiges Fachmagazin für Pumpen, Kompressoren und prozesstechnische Komponenten 

editorial 

GREEN EFFICIENT TECHNOLOGIES 

Eric Schäfer 

editor-in-chief 

Everything great in this world… 

…only happens because someone does more than he has to. This was 

once said by Hermann Gmeiner, the father of the SOS Children’s Villages. 

Doing more than necessary – this is what numerous companies are 

doing now with the aim of making their production more sustainable. 

CERATIZIT, for example, presented an ambitious sustainability strategy 

at AMB, International Exhibition for Metalworking. With this the 

company not only wants to become CO 2 

neutral by 2025, but also 

to be a leader in sustainability in the carbide and cutting tool industry. 

Sustainability was one of the three major topics at this year’s AMB. 

Further examples are shown in many articles in this issue, with which 

we once again present some trade show innovations. Tool manufacturers 

are increasingly paying attention to the efficient and careful use of 

resources in the supply chain. 

Companies like KYOCERA are working on efficient solutions such 

as determining ecological cutting values, material changes or digital 

solutions. After all, sustainability is playing an increasingly important 

role in productivity and future viability. 

MAXIMUM SAFETY. 

HIGH FLEXIBILITY. 

ROBUST DESIGN. 

MAXIMALE SICHERHEIT. 

HOHE FLEXIBILITÄT. 

ROBUSTES DESIGN. 

Hygienisch fördern 

WANGEN VarioTwin NG 

H DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH 

DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH 

H DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH 


H DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH 


DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH 


DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH 


PROZESSTECHNIK & KOMPONENTEN 

2022 

PROCESS TECHNOLOGY & COMPONENTS 

PROZESSTECHNIK & KOMPONENTEN 

The hygienic solution 

WANGEN VarioTwin NG 

PROCESS TECHNOLOGY & COMPONENTS 

ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH ENGLISH 
















The latter has been proven by LACH DIAMANT and Platinum Tooling, 

two companies that can point to their 100 th anniversary this year. 

That, too, is sustainable in a different way. Congratulations! 

Horst Lach regularly looks back on these 100 years in our 

“Poly – poly – or what?” series. This time it’s about the sustainable 

material wood, and how its processing in furniture manufacturing 

as well as in the woodworking industry has changed through the use 

of diamond tools. 

Eric Schäfer 


The independent media platform 

for energy supply, efficiency 

enhancement and alternative 

energy sources and storage 

Sustainable opportunities in 

process technology 

Circular economy in the industrial 

production process 

Topics H 2 

, Synthetic Fuels, Water, 

Solar & Photovoltaics, Wind Power, 

Bioenergy, Geothermal Energy, 

Battery Technology, 

System Integration and 

other alternative options 

Dr. Harnisch Publications 

Eschenstrasse 25 

90441 Nuremberg 

Dr. Harnisch Verlags GmbH · Eschenstr. 25 

Germany 

90441 Nürnberg · Tel.: +49 (0) 911 - 2018 0 

phone +49 - (0)911 - 2018 0 

info@harnisch.com · www.harnisch.com 

info@harnisch.com • www.harnisch.com

table of contents 

cover story 

High-performance titanium drilling, in one shot 6 

materials & tools 

Coated PCBN grade next generation technology 10 

Productivity and sustainability are not mutually exclusive 12 

Cutting insert “warns” before breakage 14 

Precision tool cutting edge cooling 15 

LACH DIAMANT looks back on 100 years – 14 th part 

The diamond as a tool in the furniture industry, as well as in wood and plastic processing industries 18 

μ-milling cutter – for high-precision requirements in mould making 21 

processes 

Retrofit unit for cryogenic process cooling 

Thomas Götz and Andreas Gebhardt, IPA 32 

New standards for eroding 35 

Making industrial production more flexible, more productive, and more sustainable 36 

machining center 

The leader in complete machining 38 

360° solutions for successful future manufacturing 39 

ANCA launches its premium, next generation machine range 40 

The answer to new requirements? New solutions 42 

The perfect machine for the entry-level segment 43 

components 

AMB premiere for the smart chuck jaw 44 

A whole new range of products dedicated to rotary / Three jaws for perfection 46 

Filtration solutions that increase efficiency and sustainability 47 

special automation 

Showroom for the automation of tomorrow 48 

Well positioned at the SPS 50 

news & facts 22 

fairs 5, 22, 24 

impressum & company finder 51 

4 no. 4, November 2022

fairs in alphabetical order 

AMB Stuttgart, Germany 

(September 10-14, 2024) 

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) 

FABTECH Toronto, Canada 

(June 11-13, 2024) 

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) 

IMTS Chicago, USA 

(September 9-14, 2024) 

JIMTOF Tokyo, Japan 


LIGNA Hanover, Germany 

(May 15-19, 2023) 

MACH-TECH and Budapest, Hungary 

INDUSTRY DAYS (May 16-19, 2023) 

METALEX Bangkok, Thailand 


MOULDING Stuttgart, Germany 

EXPO (June 13-16, 2023) 

Wood TaiWan Taipei, Taiwan 

(April 20-23, 2023) 

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 

2024 


2023 

2023 

2023 

2023 

2024 

2023 

2024 

2023 

2023 

2024 


2023 

2023 


2023 

2023 

2024 


2023 

trade fair dates as by end of October 2022; we are not responsible for reliability of these dates 

no. 4, November 2022 

5

cover story 

High-performance titanium drilling, 

in one shot 

Titanium is a high-performance material and poses a chip 

removing machining challenge. Also not all titanium is alike. 

Depending on whether it is pure titanium or alloyed titanium, the 

chip removing process behaviour differs. Mikron Tool has come up 

with different drill series that are perfectly tailored to the various 

titanium grades allowing to machine them safely with higher 

cutting performance results and longer tool life. 

Alberto Gotti PhD, 

head of research & development 

at Mikron Tool 

Titanium is highly popular in the medical technology field; due to its 

elasticity in conjunction with a high level of fatigue strength, 

titanium materials have unrivalled high bio-functionality 

Drilling into stubborn titanium is exceptionally 

challenging, partly because of the combination 

of high elasticity and tensile strength 

properties. The great toughness of this metal 

means that chip breaking is difficult to 

achieve. Due to the lower thermal conductivity, 

heat is not moved from the cutting area 

through the chip; but still needs to get rid of 

somehow. Also titanium has a propensity to 

create edge built-up which in turn can lead to 

higher levels of wear and reduce process reliability 

when drilling. Mikron Tool specializes 

in developing drilling technologies that are 

perfectly tailored to the material properties 

of pure titanium and titanium alloys. This is 

a complex task but then offers enormous production 

benefits for users. 

TITANIUM 

Titanium is by no means rare; in fact, it is the 9 th most common 

element in the continental crust. However, pure titanium is rarely found 

on earth, it is produced from titanium ore or rutile. Today we still use 

a procedure that was developed by William Justin Kroll, a metallurgist 

from Luxemburg, in 1930 for the complex production of titanium: it 

became possible to produce the metal for commercial applications 

thanks to the introduction of the industrial reduction of titanium 

(IV)-chloride with magnesium. The production process used here is 

extremely complex, as reflected by the very high price for titanium. 

Some call titanium a temperamental diva that screams when treated 

incorrectly. Titanium developed into an ultra-material for the industry 

due to its excellent properties. The application horizon is broad: 

aerospace, motor racing, medical and dental equipment, surgical 

orthopaedics and the jewellery and watch sectors all use it. Titanium 

is also ideal for eyeglass frames. In short, this metal is very popular in 

industry thanks to the broad market base. 

330.000 sh tn are processed every year. 

Titanium’s supernatural image is the 

reason for this figure. 

Rightly so because it is indestructible. 

It hardly weathers when it encounters 

oxygen because it is coated in a thin, 

transparent oxide layer. Even the most 

aggressive media, like acids, have very 

little impact on titanium. It is almost as 

light as aluminium, but much stronger, 

almost on a par with tempered steel. It 

is also biocompatible and anti-magnetic. 


cover story 

figure 1 

Titanium: “Like drilling into rubber” 

“It’s like drilling into rubber”, says Alberto Gotti, head of R&D 

at Mikron Tool. “Drilling titanium is much more challenging 

than milling; and it is even more difficult when the diameter-drilling 

depth ratio increases”. It becomes problematic 

above 3 x d. Titanium’s viscoelastic properties cause the drill 

to jam, which increases the pressure on the cutting edges. 

Material build-up on the cutting edges and margins increases 

the cutting forces which, in turn, can cause cutting edge 

breakout. Once the surface is compromised, even more material 

will build up and lead to higher friction. Also, the chip 

shape becomes problematic because the titanium chips tend 

to accumulate in the tip area and prevent smooth flowing of 

chips. In turn, this often leads to uncontrolled drill breakage. 

A further compounding factor are the high temperatures to 

which edges are exposed. From a temperature of 600 ° Celsius 

the cobalt binding matrix in the carbide substrate becomes 

‘soft’ and is no longer able to bind the hard tungsten carbide 

optimally. That leads to plastic deformation and micro-wear, 

and ultimately cutting-edge breakouts. 

Material-specific tools are the solution 

One remedy are cutting edges which need to be very sharp 

and very stable at the same time – a contradiction in itself. 

Mikron Tool has developed an ingenious specific cutting 

geometry that manages this balancing act and, as a result, 

cutting pressures can be reduced significantly. As described 

above, the heat needs to be moved from the machining area. 

The solution: two cooling channels with very large crosssections 

deliver large quantities of coolant through to the 

drill tip to guarantee constant cooling, including lubrication 

of the cutting edges. At the same time, the solid coolant 

jet flushes the chips through the polished flutes and prevents 

jamming chip backup. (figure 1) 

There is nothing new here, but: the patented special design 

of the cooling channels by Mikron Tool allows four times 

the amount of coolant quantity to be shot into the tool with 

constant pressure. This is a further key to success and stands 

for innovation in the thermal dissipation and chip removal 

technology. 

Three years of meticulous development work has gone into the sensational ‘divine’ drills for titanium by Mikron Tool 


7

cover story 

figure 2 

Also the flute profile helps significantly with the chip 

removal. But that’s not all: the R&D specialists focused on 

a carbide grade that combines wear resistance and fracture 

resistance strength. The coating is distinguished by its excellent 

wear and oxidization resistance, and as an addi tional 

benefit diminishes the tendency of material sticking. 

“Not all titanium is alike”, says Markus Schnyder, COO of 

Mikron Tool. “Anyone who wants to process this material 

efficiently needs to know it inside out. During our development 

work, we examined various titanium materials and established 

that the different titanium types differ greatly; this 

is highly relevant for the way it is machined in industrial production. 

Pure titanium (grade 1 – 4) stands out due to its high 

corrosion resistance, while it has lower mechanical strength”. 

The right drill for each grade of titanium 

Markus Schnyder: “Alloyed titanium (grade 5 and higher) is 

incredibly strong but has low ductility. We worked like crazy 

to master these differences with chip removal technology. 

Three years of meticulous development work lie behind us. 

Our passion and the insights we gained have led us to a perfect 

solution: two specific geometries, one for pure titanium grades 

and one for titanium alloys. Thus, we can guarantee perfectly 

controlled chip removal, high drilling speeds and precisely 

repetitive processes with optimum machining quality 

for these difficult titanium materials. The right and specific 

drill for each titanium grade. This is our answer for handling 

this complex and ‘divine material”. 

Crazy drill cool titanium – twice as fast 

The new Crazy Drill Cool Titanium series is available in a 

diameter range of 1.00 to 6.35 mm (.04" – .250"). Mikron 

Tool has developed short drills with 3 x d and drills with 6 x d 

for pure titanium (CrazyDrill Cool Titanium PTC) and 

drills with 6 x d and 10 x d in combination with a special pilot 

drill for titanium alloys (CrazyDrill Cool Titanium ATC). 

(figure 2) 

For the cost-effective production of titanium components, 

tools are required which are specially adapted to the material 

properties of the various titanium grades. 

Titanium material as well as the workpiece are expensive, 

which is why high process reliability and calculable tool 

life are so important. If the latter can be improved, so much 

the better. Mikron Tool’s new high-performance drills for 

titanium have up to three times longer tool life and work with 

twice the feed than current competitors. Another outstanding 

aspect: with the ATC-version drilling is completed in one 

shot, without multiple machining steps. 

Things are heating up in the Mikron Tool think tank; 

drill into titanium even more quickly and safely; 

twice as quick and 2 – 3 times longer tool life in 

combination with excellent process reliability 

The result is impressive and proves once again, that 

Mikron Tool is a technological leader and will defend its 

position by machining difficult materials successfully. “We 

love getting the best out of our tools for our customers. 

Nothing is too ‘crazy’ for us”, says Alberto Gotti. 

further information: www.mikrontool.com 


Producing threads in high-tensile steels 

Top-class tap for difficult-to-machine steels 


Machining high-tensile steels presents particular 

challenges, as the tool must also achieve a long tool life 

in addition to top process reliability and performance. 

When it comes to problems of producing threads in 

such demanding materials, the Hoffmann Group has 

now developed a new tap that easily masters this task: 

the GARANT Master Tap Steel HT. 

In the case of high-tensile materials such as Toolox and 

Hardox, blind hole threads can be produced up to a maximum 

thread depth of 2xD. For materials with a somewhat 

lower tensile strength, thread depths of up to 2.5xD in the 

blind hole version and of up to 3xD for through hole threads 

are also possible. 

Thanks to the strong spiral point, the through hole machine tap remains stable and reliable 

even when under high cutting force loads 

2: The cylindrically stepped guide thread of the blind hole machine tap prevents chip jams, 

which can lead to break-away of the thread flanks 

This specialist in the thread production segment is made 

from a high-quality and rigid HSS-E-PM tool material and 

is protected against process heat by a hard and low-friction 

multi-layer coating. A special feature is that two different 

coatings are used per application in order to adapt the process 

even more effectively to meet various different requirements. 

The tap for blind hole production is therefore coated 

with titanium aluminium nitride (TiAIN), while the one 

for through hole production is coated with titanium carbon 

nitride (TiCN). 

The geometric feature of the cylindrically stepped guide 

thread is relied upon in order to avoid the risk of chip 

jamming during the production of blind hole threads – which 

can lead to break-away of the thread flanks in the case of 

high-tensile materials. The through hole tap, on the other 

0hand, remains stable and reliable even under high cutting 

force loads thanks to its strong and optimally crafted spiral 

point. 

With the new GARANT Master Tap Steel HT, M, MF and 

G threads can be produced both as blind hole and through 

hole threads. The taps with the M and MF design are manufactured 

only in the 6HX and 6GX tolerance, in order to counteract 

wear in case of abrasive materials. This results in reliable 

threads that are true to gauge being produced, and a long 

tool life. The GARANT Master product range was started 

by the Hoffmann Group 2015 aiming to provide particularly 

powerful and reliable tools for high-performance cutting. 

Since then, GARANT Master tools have opened up new performance 

classes, including the GARANT Master Steel HPC 

milling cutter, the GARANT Master Steel Feed and Speed 

solid carbide drills and the GARANT Master Steel Deep 

solid carbide deep hole drill. The product range now comprises 

a wide range of high-performance tools for applications such 

as drilling, milling and thread tapping in various materials, 

including steel, aluminium and stainless steel. 

further information: www.hoffmann-group.com 


9


Coated PCBN grade next generation technology 

Hardened steel turning 

Mitsubishi Materials has developed a new and 

innovative coated PCBN insert grade, BC8210. In 

doing so it has extended its comprehensive range of 

turning inserts. The grade incorporates the company’s 

state of the art coating technology that provides outstanding 

wear resistance, as well as providing a 

product that improves productivity and usability. 

The new grade is suitable for continuous through to light interrupted 

cutting. BC8210 exhibits excellent chipping, flank 

and crater wear resistance, thereby providing a stable machining 

process at high speed cutting conditions. A combination 

of the newly developed AlCrSiN-base coating that 

absorbs impacts, and the TiAlSiN-base coating which has 

excellent wear resistance, provides stability during continuous 

through to low interrupted cutting applications. 

At depths of cut up to 0.35 mm and at cutting speeds up to 

300 m/min means a market leading range of applications can 

be covered by a single grade. This brings a simplification of 

choice for production and CNC programming and reduces 

inventory costs. 

High technology substrate and coating 

The new line of CBN inserts delivers a variety of performance 

and benefits through constant refinement and R&D work. 

This has created a new sintered substrate containing both 

micro and medium grain CBN particles, but with an ultra 

micro-particle binder. This new binding technology in the 

substrate provides ultra heat resistant and prevents sudden 

fracture by eliminating the potential for linear crack development. 

With the cutting forces being dispersed radially by 

this new binder formula, BC8210 excels when machining 

extremely hard steels. Additionally, this new substrate 

enables a wider range of applications, provides greater chipping 

resistance and wears less. 

This new technology has been applied to a specially developed, 

multi-layer PVD coating that the BC8210 grade utilises. 

This new coating includes a TiAlN bottom layer that greatly 

improves adhesion between the base layer and the CBN substrate 

and provides exceptional peeling resistance. Above this 

layer is an additional TiAlN layer that provides outstanding 

chipping and crater wear resistance. Together with a gold 

coloured, TiN top layer for easy identification of used edges, 

BC8210 achieves high performance, speeds and reliability 

over a wider range of hardened steel machining applications. 

Choice of chipbreakers 

BC8210 inserts are available with 4 different chipbreakers; 

the FS and GS types for general cutting, the GH for higher 

feeds and depths of cut and finally the TS type for light interrupted 

machining. 

TiN-coating 

AlCrSiN-base coating 

Gold colour aids easy identification 

of used edges 

strong resistance to chipping, 

absorbs impact forces 

TiAlSiN-base coating 

excellent wear resistance 

and abrasion resistant 

layer 

TiAlN-base coating 

PCBN sintered body 

improved strength of adhesion 

to the PCBN substrate 

prevents peeling 

exclusive BC8210 

sintered substrate 

further information: www.mmc-hardmetal.com 



Stable, process-safe and 

highly efficient 

CAN YOUR 

LIFT TABLE 

DO THIS? 

With the MultiEdge T90 PRO4 tangential corner and face milling 

cutter, LMT Tools is expanding its milling system for demanding 

cutting tasks. 

A high metal removal rate, great process reliability and economical operation: 

this is offered by the MultiEdge T90 PRO4 tangential corner and face milling 

cutter, which LMT Tools has expanded to include a highly efficient “porcupine 

mill” variant and cutting inserts with chip breakers. This is suitable for rough 

milling and semi-finishing operations on machine components such as pump 

housings, machine frames and guide rails. 

The new porcupine cutter 

variant of the MultiEdge 

T90 PRO4 from LMT Tools: 

process-reliable, powerful 

and efficient for roughing and 

semi-finishing operations 

For cast iron, steel and stainless steel 

“New to the MultiEdge T90 PRO4 are cylindrical milling cutters, which are 

offered in a diameter range of 50 to 80 mm, as well as inserts with chip breakers,” 

explains Hanjo Gissler, senior product manager for milling. The inserts allow 

cutting depths of up to 11.5 mm and are suitable for machining cast iron 

(ISO-K materials) as well as steel (ISO-P) and stainless steels (ISO-M). 

The inserts, manufactured using the press-to-size process, have four usable 

cutting edges that are numbered for easy and safe handling. Due to their unequal-split 

mounting in the milling body, they operate with very low vibration. 

The tangential installation position enables a particularly favorable ratio of contact 

surface and clamping force and thus maximum stability. “Even at a high 

chip removal capacity, the tools are thus extremely process-reliable,” emphasizes 

Gissler. Their positive rake angle also results in excellent cutting performance 

and thus low power consumption on the machine. 

Significantly reduced cycle times 

Another factor for increasing efficiency is the optimum ratio of tool diameter to 

number of teeth. In combination with the high feed rates that can be realized, 

enormous metal removal rates are thus possible. “This shortens cycle times and 

reduces overall process costs,” says Hanjo Gissler. This has also been shown 

by the first practical applications of the new tools. “A mechanical engineering 

customer from France was able to significantly reduce both its tooling costs and 

machining time by using the MultiEdge T90 PRO4,” Gissler relates, “the latter 

by a spectacular 80 %.” 

PRO165SV is shown lifting 

a 5-gal (18.9 l) water jug, 

which is 41.7 lbs (18.9 kg). 

The PRO-SV from Aerotech is: 

• Currently the most precise lift table on 

the market 

• The only lift table with long travel and 

up to 60 kg moving mass 

• Easy to assemble with dynamic 

performance 

The PRO-SV is ideal for: 

• Height-limited applications 

• Combining several positioning tables 

on top of each other 

Specific applications: 

• Sample positioning in beamline/ 

synchrotron positioning 

• Wafer inspection 

• Surface measurement 

further information: www.lmt-tools.com 

See for yourself at 

de.aerotech.com/prosv


Productivity and sustainability are not 

mutually exclusive 

The KYOCERA Group presented 

a variety of cutting solutions 

for industrial machining 

and manufacturing at the AMB 

exhibition in Stuttgart. As well 

as top innovations for the construction 

of electric vehicles, these 

also include solutions for energy 

production (such as wind power 

technology). 

Key words like reliability, precision, 

versatility and sustainability are on the 

focus: as a tool manufacturer, Kyocera 

pays particular attention to the efficient 

and careful use of resources 

in the supply chain. In addition the 

company is pushing to find more efficient 

solutions like identifying economical 

cutting values, material 

changes or digital solutions, in order 

to operate more sustainably. 

Minimising CO 2 

emissions 

The KYOCERA Industrial Tool Group 

is pursuing the long-term goal of reducing 

CO 2 

emissions within the 

whole supply chain in the cutting tools 

sector. Individual steps range from 

product development to purchasing, distribution, sales, processing, 

resource recovery and re-use, through to disposal. 

Five key aspects for climate neutrality in cutting tools 

Through the ever-changing world, as well as the associated 

new set of challenges, the company expands its tool and service 

portfolio, and pursues an even more economical and 

sustainable approach. Additionally, the increase in productivity 

lowers CO 2 

emissions. For example, a CO 2 

emission 

calculator helps this. The tool calculates the saving potential 

in machining through the tool selection and individual 

parameters. 

Stator housing units made of aluminium with various tools 

that are necessary for the construction of such a housing unit 

(PDK stepped reamers; boring tools; milling cutters) 

Highly efficient processing to save energy 

High-quality processing with new tool solutions allows 

new ways of thinking. Here, for example, hidden processing 

errors, can be uncovered, eradicated and thus resources 

can be saved. In this context the High Feed Milling Series 

(MFH) has been providing immense savings in production 

worldwide since years. Kyocera now presented an updated 

lineup at AMB with cutting depths of up to 2.5 mm. In short, 

this means that there is an enormous increase in productivity 

through the development of high value-added tools. At AMB 

it was also possible to view tool portfolio extensions for nextgeneration 

components and for environmentally friendly 

industrial components. 



Use of DX technology 

“From a world of reflecting after processing to a world where we can see things 

before processing” – this is a quote from the Kyocera headquarters in Kyoto 

regarding digital transformation. The goals of this transformation are to reduce 

machining times, optimise machining conditions, identify machining problems 

and take countermeasures in advance. In order to actually implement these 

goals the DX technology offers a dynamic and sustainable range of tools through 

analysis technologies. An example of this is the AI-based wear analysis assistant. 

The type of wear is determined via photo upload of the indexable insert. The tool 

will first be launched in Japanese and soon will be available in other languages. 

Easy solutions for electric vehicles 

In order to be able to generate a long range and thus attractiveness with heavy 

electronic vehicle batteries, a comprehensive weight optimisation of the structural 

FILTECH 

February 14 – 16, 2023 

Cologne – Germany 

The Filtration Event 

www.Filtech.de 

Platform 

for your 

success 

Easily combinable compartments allow for 

sufficient space in the smallest of spaces 

components is essential. KYOCERA Unimerco has been working with specially 

developed tools for aluminum with low silica content for decades. In this way 

not only efficiency and dimensional accuracy are taken into account, but also 

the demand for the lowest possible burr formation, especially for thin-walled 

structures. Here Kyocera’s standard tools are also used as special tool solutions 

with PCD cutting edges that meet the high and strict requirements of the 

automotive industry. 

RE•NEW TM program expansion 

KYOCERA Unimerco’s concept for tool maintenance offers a lot more than 

just the regrinding of tools. KYOCERA Unimerco established its first regrinding 

service back in the 70’s. Over 15 years the company has offered this product, 

which is constantly improved to meet current standards. Tools with the predicate 

RE•NEW TM are guaranteed to perform the same or even better than a new 

tool. Up to 75 % savings on processing costs are thus possible. The returned tool 

will not only have the same quality, but also the same performance features. 

Delivers 

solutions for 

current 

and future 

challenges 

From October 2022 on it will also be possible to overhaul the MagicDrill DRAs 

high performance drill bits of all sizes in the GM version – quickly, easily and of 

course under the promise of RE•NEW TM . 

further information: www.kyocera.co.uk 

Your Contact: Suzanne Abetz 

E-mail: info@filtech.de 

Phone: +49 (0)2132 93 57 60


Risk detected and averted: 

Cutting insert “warns” before breakage 

Machining steel is anything but simple. Experienced 

machining specialists all agree on this and are 

open to any solution that helps them turn ISO-P steel. 

That is why CERATIZIT has put its turning grades 

to the test and “refined” them where necessary – with 

long-term success. 

ISO-P steels are by far the biggest material group in metal 

machining as it includes materials such as ductile, low-carbon 

steels right through to high-alloy steel grades. Added 

to this are variations in hardness, application types and 

machining conditions during turning operations. To make 

choosing an appropriate indexable insert grade easier, the 

turning specialists at CERATIZIT have developed their own 

indexable insert grades and tailored them to the enormous 

variety of ISO-P materials. 

For steely types and tough nuts 

“The indexable inserts for our grades CTCP135-P, CTCP125-P 

and CTCP115-P have significantly boosted output in comparison 

with their predecessors: 20 % longer service lives 

speak for themselves and make our turning tools even more 

appealing,” says Stefan Karl, product manager Cutting Tools 

at CERATIZIT. Anyone who fails to look closely enough at 

alternatives and best-practice when selecting an indexable 

insert grade is squandering major potential savings. 

To enhance productivity for its customers CERATIZIT has 

rethought its new turning grades, from the substrate to the 

geometries, right through to the Dragonskin coating – for optimal 

process security and hardness of cutting edges so that 

they can withstand the extreme temperatures in the cutting 

zone without plastic deformation. This ensures that they are 

prepared for every challenge, regardless of whether extremely 

hard or tough materials need to be machined. 

Dragonskin produces hard facts 

The innovative Dragonskin coating is crucial to the performance 

capability of the new steel turning grades. Its optimised 

structure is designed to increase tool life and reduce 

machining time. Mechanical post-treatment enables 

CERATIZIT to achieve the layer surface’s unique state of 

residual stress, which pays off in terms of increased process 

security, especially in large-scale production. 

ISO-P steel is not so tough: the new CTCP135-P, CTCP125-P 

and CTCP115-P steel turning grades are specially designed 

for this material 

Wear can be detected in good time thanks to the 

indicator layer of the new Dragonskin coating 

The CTCP115-P (ISO P15) grade is particularly suitable for 

smooth cuts with stable cutting conditions and continuous 

cuts. CERATIZIT has also provided grades CTCP125-P (ISO 

P25) for turning operations from finishing to rough machining 

and CTCP135-P (ISO P35) for cuts in unstable and difficult 

conditions. 

Process-secure thanks to wear detection 

When approaching the end of its life cycle, every cutting 

insert experiences a drop in performance. If this is detected 

too late, the machining quality may already have been 

reduced significantly. “This is even worse if the tool is pushed 

right to its limit where it can fail in the middle of a process. In 

this case the defective cutting insert is the least of your problems. 

The damaged workpiece presents a much more serious 

issue,” says Stefan Karl knowingly. However, if the user 

identifies the extent of wear directly using the new indexable 

insert indicator layer, they can replace it in a timely manner. 

“A lot of our customers wanted this feature, which is why 

we have incorporated it into the latest generation of our steel 

turning grade in the form of the special Dragonskin coating 

– for stable and conflict-free processes!” 

further information: www.ceratizit.com 


Turns on, stays cool: 

Precision tool cutting edge cooling 


Optimised cooling lubrication: with the DirectCooling system from CERATIZIT, two coolant holes that are aimed 

at the cutting edge cool and lubricate extremely efficiently, and clear away chips as quickly as possible – 

now also with the MaxiLock-S DC turning tools holder 

What is good for the inside can also be good for 

the outside. That is what the development specialists at 

CERATIZIT thought when upgrading the tried-andtested 

MaxiLock-S turning tool holder to the Direct- 

Cooling holder. Two nozzles apply coolant now directly 

to the cutting edge – enabling tools to give wear the 

cold shoulder. 

More is more – this principle still dominates coolant delivery 

but change is coming. With a focus on sustainability and 

the efficient use of resources, the smart successors to flood 

coolant/lubrication are already waiting in the wings. Accurate 

not liberal, precisely applied not spurted on – these are the 

arguments in favour of the DirectCooling (DC) system from 

CERATIZIT that bring a minimalist approach to machining 

companies. 

Precisely on the hot zone 

The typical scenario in a turning center is that a hose distributes 

the coolant extensively on the machining area. The new 

MaxiLock-S DC turning tool holders, which supplement the 

DirectCooling (DC) system, provide a different way of doing 

things. The holders feature two internal holes ensuring that 

the coolant is applied precisely to the cutting edge, with one 

hole targeting the rake face from above and the other the 

flank from below, proving that not all good things come from 

above. By contrast, flank cooling boosts the service life by 

60 % compared with cooling exclusively on the rake face. 

DC can also now do it 

“We wanted to take what has since became the norm for 

grooving holders and apply it to our turning tool holders 

for external turning applications too. This resulted in the 

MaxiLock-S DC range, which allows customers to boost 

both general process security and cutting values thanks 

to targeted cooling. Compared with conventional cooling, 

DirectCooling achieves service life improvements of around 

65 %, regardless of material and machining application,” 

explains Stefan Karl, product manager Cutting Tools at 

CERATIZIT. Also the insert seat has been reworked. This 

makes it possible to clamp the turning indexable insert with 

even more stability, which reduces wear on the cutting edges 

and creates better surfaces on the workpiece. 

DirectCooling can be used for any application and works 

from a coolant pressure of just 10 bar. The coolant must only 

be transferred via the turret of the turning center or turningmilling 

center, which is the case in most recent machines. 

“The higher the pressure, the better chips are broken and 

cleared away. This is particularly beneficial to those who 

machine steels and is also excellent in combination with our 

new ISO-P indexable insert. However, the MaxiLock-S DC 

is just as comfortable on stainless and difficult-to-machine 

materials,” says Stefan Karl. 

Flexible and stable with a system 

Interference contours are a common problem during 

machining, but not for the holders from the DirectCooling 

series. Their lengths have all been ideally matched to one 

another and also offer optimal stability and unlimited flexibility. 

The nozzles of the new MaxiLock-S DC turning tool 

holder can also be replaced – for long, accurate cooling. 



15


New coating 

With the new RC2 and RC4 coatings, Paul Horn 

GmbH exhibited new developments in the field of highperformance 

tool coatings. The high toughness and 

hardness allow the machining of steels at high cutting 

speeds and lead to a significant increase in tool life. 

The high temperature resistance enables productive use in 

dry machining as well as with minimum quantity lubrication. 

Numerous tool systems are available from stock with 

the new HiPIMS coating. In-house coating enables fast 

delivery times even for special tools. 

With the new RC2 and RC4 coatings, Paul Horn GmbH 

is exhibiting new developments in the field of 

high-performance tool coatings 

Horn is constantly investing in new and modern technologies. 

In 2015 the company CemeCon delivered the world’s 

first of three HiPIMS systems to Horn. The High Power Impulse 

Magnetron Sputtering technology brings specific advantages 

and new possibilities in the coating of precision 

tools. It enables the build-up of dense, compact coatings that 

are very hard and tough. The coatings have a homogeneous 

structure and uniform coating thickness even if the tool 

geometry is complex. Research and development of new and 

existing coatings and technologies is a central component of 

success. Horn employs a team of engineers who work exclusively 

on this subject. Since in-house coating started, research 

and development projects have been carried out in cooperation 

with equipment manufacturers. 

further information: www.phorn.de 

Horn is constantly investing in new and modern technologies 


Groove and cut-off milling system 


Paul Horn GmbH presented 

a completely new generation 

of groove and cut-off milling 

system at AMB 2022. The newly 

developed tool system enables 

highly economical and productive 

milling performance. Each 

precision-ground indexable 

insert offers four usable cutting 

edges. This means that the 

user no longer needs different 

inserts to equip the milling cutter 

body. 

Horn offers the positive inserts 

with round chip breaker groove in 

the new grade RC4G. This grade 

enables high cutting performance 

during the milling process. The 

M475 system complements the existing 

Horn milling systems M310, 

382 and 383. The special surface 

treatment of the milling cutter bodies 

offers a high level of protection 

against abrasion from chips. 

The cutter bodies are available 

from stock as side milling cutters, 

shell milling cutters and screw-in 

milling cutters. The shell and 

screw-in milling cutter variants are 

equipped with an internal coolant 

supply. Horn offers the side milling 

cutters in diameters from 80 mm to 

200 mm. The cutting and grooving 

width is optionally 5 mm (0.197“), 

6 mm (0.236“) or 8 mm (0.315“). As 

shell mills, the tools are available in 

diameters from 63 mm (2.480") to 

200 mm (7.874"). The groove widths 

are the same as for the side cutter 

variant. The screw-in cutters are 

available for groove widths from 

5 mm (0.197") and diameters from 

40 mm (1.575") to 63 mm (2.480") 

as standard. The effective number 

of teeth of all variants depends on 

the respective diameter. For example, 

it is zeff = 2 for the 40 mm 

(1.575") diameter shell mill and 

zeff = 13 for the 200 mm (7.874") 

side cutter. The large number of effective 

cutting edges also contributes 

to the economic efficiency of 

the new M475 milling system. 

further information: www.phorn.de 

The precision-ground indexable insert offers four usable cutting edges 

The completely new developed tool system M475 enables 

highly economical and productive milling performance 


17


LACH DIAMANT looks back on 100 years – 14 th part 

Poly – poly – or what? 

Yeah, here I come… 

the diamond as a tool in the furniture industry, 

as well as in wood and plastic processing industries 

Yesterday evening, in the middle of the daily news 

show, I jumped up spontaneously – and my wife noted 

with surprise that I suddenly grabbed paper and pen. 

“Yeah, here I come...” was what I jotted down as the 

title of my next “Poly – poly or what?” article. 

No worries, I will not write down my full life story, but I 

might have been inspired by a report on TV: “Despite Corona, 

the German furniture industry, especially kitchen furniture, 

is doing well.” 

That comes as no surprise, considering the lockdowns, 

home office and confinement to the privacy of our homes. 

On top of that, no vacations, no money spent in restaurants 

and bars. A continued focus on our own home surroundings 

and constant activities in the kitchen inspire a change in 

furniture. 

Obviously – and quite natural for Horst Lach – diamonds 

come into the mind, both in a narrower and in a broader 

sense, and in connection with the machining of wood and 

plastic composites. 

Doing so, I do not yet know who my readers will be, so 

please forgive me for this. Our example today, the diamond, 

is by now known as dia tool within the industry. 

It all began 44 to 45 years before today’s date (1978/79). Actually, 

it already started approximately 50 years ago, in 1973, 

when General Electric was the first manufacturer to offer 

polycrystalline diamonds under the trademark of “compax”. 

A development I experienced personally, and which I can 

only share due to my advanced age and my own profession. 

Therefore, I can understand how, during a continued 

industrial revolution, an ever-increasing demand for mass 

production ignited the desire for abrasive cutting tools with 

ever-greater stability – in the end for the hardest of all things – 

DIAMOND. And this not only in the metal industry, and in 

machine construction, but also for machining of all wood 

materials. 

In the mid/end 60’s, a “high-flyer” cutting material replaced 

previously used high-speed steel (HSS) for the first time – the 

very name of a trademark of Krupp company in Essen reflected 

this “desire” for the hardest of all things – Widia 

(based on the German term “wie Diamant” = like diamond). 

And then – just when “hard metal” had established itself 

in the market, due to a parallel and fast-paced development 

of resin bond diamond grinding wheels – out of the 

blue, a manufacturer named Lach-Spezialwerkzeuge GmbH 

(LACH DIAMANT) presented a complete dia tool and saw 

programme for the wood and plastic processing industry at 

LIGNA 1979. 

LACH DIAMANT 

at LIGNA 1979 



LACH DIAMANT 

at LIGNA 1979 

Under the slogan “Your Way to Diamond Economics”, Lach- 

Spezial offered diamond tools with tool times far-superior to 

carbides (up to several hundred times), according to the regulations 

of the trade association’s “BG-Test and BG-Form”. Despite 

the initially high tool price, diamond tools proved to be 

efficient from the start on – straight-edged dia cutting edges 

were priced at 70-80 DM (Deutsche Mark) per mm, profile 

cutting edges at 100 DM (Deutsche Mark) per mm. Thanks 

to a close collaboration between LACH DIAMANT and 

General Electric, the prices for polycrystalline diamond inserts 

could be lowered significantly during the 1980’s. The 

development of new markets for PCD tools in the aviation 

and composite industry followed. 

As a typically medium-sized industry, furniture and kitchen 

furniture manufacturers took the lead in utilizing these versatile 

and cost-reducing production and design options and 

became the top customers for polycrystalline diamond cutting 

tools and saws; even ahead of the aluminium-machining 

automobile industry. At that time, the control technology 

of wood working machines was superior to controls of 

metal working machines, e.g., through the early switch from 

numeric (NC) to CNC controls. 

However, I should not forget to mention that not only furniture 

manufacturers profited from the new cutting material 

diamond – but also their employees. For example, now it was 

no longer required that a master craftsman had to be present 

for changing the tool during each shift in a 3-shift operation, 

a common practice for edging machines. Without any resharpening, 

the diamond tool would run for 3 to 6 months! 

From the beginning to the end of its tool life, there was no 

loss in sharpness, which proved to be a sales-promoting factor 

and a special advantage, especially for decoratively coated 

MDF boards (medium-density fibreboards). 

During a visit in the USA – after founding LACH DIAMOND 

INC. in Grand Rapids, Michigan – I witnessed the production 

of a massive, 40 mm thick, 1.5 m-diameter oak table top 

in one of the larger “furniture shops”. Two very muscular 

men had to use all their strength to circle this table top with 

a vertical Knoevenagel milling cutter. I will never forget this 

image. Months later, the new diamond tool allowed for only 

one man to do the same job without any pause or break, and 

without the previous struggle. 

Diamond 

tools with 

tool times 

far-superior 

to carbides 

However, I must admit that the respective workers were 

not that grateful to me and did not look at me that friendly; 

as I found out afterwards, their heavy labour bonus had 

been cut. 

Horst Lach 

further information: www.lach-diamant.de 


19


New cutting materials for reaming and fine boring, 

quickly available MN reamers 

MAPAL presented at AMB the two new cutting 

materials HP016 and HP018. They are specially 

designed for the particular requirements of reaming 

and fine boring high-alloy and stainless steels as well 

as cast steel and hardened steel. 

The HP016 cutting material is suitable for all machining 

operations with a slightly interrupted cut, while the HP018 

cutting material is used for continuous cutting conditions. 

Both are based on a silicon doped PVD coating on two different 

carbide grades with low cobalt content, which stands for 

extreme wear resistance and high dimensional accuracy. 

The new cutting materials will be used for the market 

launch in the reamers of the MN series, among others. These 

tools stand for the very highest accuracies, can also be used 

optimally for hard reaming and for reaming stainless steel 

thanks to the new cutting materials and are now available 

within ten working days. They function according to the 

“MAPAL principle” – with one indexable insert and guide 

pads arranged around the circumference, which are made of 

carbide, cermet or PCD depending on the application. 

E-mobility: basic, performance and expert solutions 

Tool solutions for e-mobility are of particular importance 

in the automotive sector. For demanding components that 

will be produced in high quantities, MAPAL presents different 

machining levels: Basic, Performance and Expert. The 

new classification describes the different machining solutions 

depending on the quality requirements, number of units and 

investment. The Performance Line is aimed at series production 

and focuses on machining with special tools. It is mainly 

used when new components are to be produced efficiently 

and economically on existing systems. 

FaceMill-Diamond-ES and NeoMill-T-Finish 

increase economic efficiency in aluminium milling 

MAPAL expanded its aluminium milling programme with 

two new products. The FaceMill-Diamond-ES is a versatile 

all-rounder that ensures high economic efficiency and sustainable 

process reliability in demanding production conditions 

with smaller quantities and changing component types. 

The indexable insert milling cutters of the new NeoMill- 

T-Finish series provide a significant increase in the economy 

and efficiency of finish machining in series production. The 

finish milling cutter with exchangeable inserts functions according 

to the plug & play principle: customers change the 

inserts directly on site without having to adjust them afterwards. 

In addition this also means that fewer tool bodies have 

to be kept in stock. 

The new HP016 and HP018 cutting materials from MAPAL 

are specially designed for the particular requirements of 

reaming and fine boring high-alloy and stainless steels 

as well as cast steel and hardened steel 

The “Performance” tool package for machining stator housings 

for electric motors is optimised for medium production 

quantities; picture: the machining solution with HSK-63 

What makes the new milling cutter unique is a patentpending 

system of insert arrangement, which results in a 

homogeneous wear pattern of the cutting edges, longer tool 

life and thus a low cost per part. 

Titanium milling: 

NeoMill-2-HiFeed90 + OptiMill-Tro-Titan 

The tool programme for titanium machining is expanded by 

two efficient milling tools. The five-edged trochoidal milling 

cutter OptiMill-Tro-Titan is characterised by maximum 

metal removal rate and shines with excellent surfaces due 

to unequal spacing and unequal pitch of the cutting edges. 

It is designed for trochoidal milling in partial cutting, trimming 

and for cutting depths up to 3xD. The new radial insert 

milling cutter NeoMill-4-HiFeed90 will be available as 

an end mill, screw-in milling cutter and milling cutter head 

from January 2023. The universally applicable high feed 

milling cutter stands for high productivity and is characterised 

by the highest stock removal rates, very high feed rates 

and large chip depths. 

further information: www.mapal.com 



μ-milling cutter – 

for high-precision requirements in mould making 

Mould making plays a key role in many industries. 

Mould makers place high demands on cutting tools – 

after all, they are a key component in ensuring product 

quality. This is why Gühring presented a new milling 

cutter range for high-precision finishing requirements 

at AMB 2022. 

The combination of new geometry, adapted coating system 

and ultra-hard substrate makes the high-precision milling 

cutters so successful when used in hardened tool steel. 

Maximum angular and fit accuracy 

Whether plastic, metal, glass or chocolate – moulding is what 

turns raw materials into products. Because these moulds produce 

the surfaces of the finished components, maximum precision 

is required here: only a perfectly manufactured mould 

can produce a final product with tolerances and surfaces that 

meet the required quality without reworking. For perfect part 

quality, mould makers rely on tools that guarantee process reliability, 

precision and repeatability. The Swabian tool manu - 

facturer Gühring meets precisely these requirements with 

a new range of high-precision milling cutters: the μ-precise 

solid carbide milling cutters have a stable core geometry and 

an optimised flute profile. Both reduce displacement during 

milling and ensure stability which is reflected in a very high 

contour accuracy. This makes the tools suitable for finishing 

high-precision fits and guides with exact angular accuracy. 

Safe chip removal during the milling process was another 

focus during tool development as a basic requirement for 

good surfaces. The structural dimensions and neck transition 

geometries of the new milling cutters have therefore been 

optimised for use in deep and narrow contours. All micro 

With the new G-mold μ tool range all milling 

processes in mould making can be covered 

milling cutters in the new range also consist of revolver 

blanks with GühroJet periphery cooling. With this innovative 

technology for internal cooling, chips are removed directly 

and safely from the machining zone by air, minimum 

quantity lubrication (MQL) or cooling lubricant. 

Harder substrate, extremely smooth layer 

Because tool and mould making involves machining highstrength 

and hardened steels, Gühring has adapted its carbide 

substrate to these materials with the new high-precision 

milling cutters: the cutting material is now around 200 HV 

harder and finer-grained. This ultra-hard solid carbide substrate 

guarantees very good edge stability and thus processreliable 

service life in hard machining. The precision blanks 

also have optimised shaft tolerances in the h5 range and are 

μ-precise in diameter, concentricity and roundness. The radius 

tolerances are even in the range of +- 5 μm. The coating system 

has also been specially adapted for mould making: a 

Perrox coating produced using the HiPiMS process makes 

the tool surfaces extremely smooth and therefore very resistant 

to wear. Thanks to this combination of carbide, coating 

and geometry, the new high-precision milling cutters promise 

a significant increase in performance – both in soft and harder 

materials up to 65 HRC and even in high-alloyed or powder 

metallurgically manufactured tool steels. 

Every milling application covered 

With its new G-Mold μ tool range, Gühring can now cover 

all milling processes in mould making. The solid carbide 

full-radius milling cutter “G-Mold μ65 B”and the highprecision 

torus cutter “G-Mold μ65 T” are perfect for copy 

milling and finishing of moulds and mould inserts made of 

hardened steel up to 65 HRC. The cylindrical high-precision 

finishing cutters “G-Mold μ65 F” for hardened workpieces 

and “G- Mold μ48 F” for soft workpieces enable the optimal 

angular accuracy and exact fits when finishing guides and 

pockets in moulding plates. The new μ-precise micro milling 

cutter “MikroMill μ55 U”meets high demands in the micro 

range: very high-quality surfaces can be achieved with 

the tightest tolerances and precise concentricity. An FEMoptimised 

radius angle transition also ensures maximum 

radial rigidity and low displacement during micro-milling. 

The innovative GühroJet internal cooling increases the 

service life of the tool and ensures process reliability. 

The new range offers a high degree of flexibility with over 

350 different dimensions, a wide range of full or corner 

radii as well as corner chamfers and different versions for 

hard and soft materials. Because quality counts above all in 

addition to quantity, the tool manufacturer has invested specifically 

in specialised production and measuring technologies 

at its site in Germany – for tools that customers in tool 

and mould making can rely on. 

further information: www.guehring.com 


21

news & facts 

fairs 

Filtration in machining processes 

For health, safety, and efficient plant engineering 

Avoiding contamination, ensuring quality, safety, and 

health: filtration plays a decisive role in the processing 

of materials. Visitors to FILTECH will gain insights 

into all areas of filtration and separation of all types 

of media. The combination of trade show and congress 

offers everything they need for efficient filtration 

in their processes. The next FILTECH will take place 

February 14 to 16, 2023. 

Whether metals, glass, or ceramics: chips, dusts, and mole 

cular pollutants endanger the health of employees and the 

environment, but also the equipment. In many primary and 

secondary processes, filtration processes therefore play a 

decisive role in ensuring the quality of the product. Separation 

technology is also crucial for long service lives of the 

tools and equipment used. Above all, clean ambient air must 

be ensured for the health of the personnel. 

Especially in metal processing contamination of the materials 

can occur quickly. In forging, plasma or laser cutting 

and engraving, dry, clean, and oil-free air ensures quality, 

precision and economy. Air filters increase the service life of 

equipment and also determine compliance with applicable 

regulations and laws, for example with regard to CO 2 

emissions. 

Filters are also used in cooling and heating processes or 

in laser beam path purging. 

Equipment and components, services, and know-how for 

the diverse filtration processes in the processing of metals, 

glass, ceramics and other materials are offered by FILTECH 

exhibitors. At the combination of trade show and congress, 

visitors receive industry-specific expertise and opportunities 

for personal exchange about filtration and separation of all 

types of media. 

Focused trade fair with over 440 exhibitors 

From February 14 to 16, 2023, FILTECH will once again open 

its doors to visitors at the exhibition center in Cologne, less 

than a year after the previous date in spring 2022. Due to the 

Corona pandemic it was necessary to deviate from the usual 

one-and-a-half-year interval. “The innovative power of the 

filtration industry is very high”, explains Suzanne Abetz 

from organizer FILTECH exhibition Germany. “At FILTECH 

2023 the trade audience will once again be presented with 

numerous innovations – also from many new exhibitors who 

are taking part for the first time.” 

Visitors will be offered a wide range of products and 

services: in addition to separation and separation technology, 

the program also includes measurement technology, ana 

lytics and laboratory supplies, as well as news from science 

and research. Industry giants will be represented as well 

as specialists and numerous research and development 

institutes. 

Since 2020 the desire for clean, hygienic ambient air has 

risen sharply, not only in production, numerous exhibitors 

are also focusing on products such as stationary air cleaners 

and systems in a wide variety of dimensions. HVAC systems 

from the exhibitors achieve separation rates of over 99.9 % 

and can support operators with energy-efficient solutions for 

all applications in operational buildings. 

Whether air purification or filtration processes in production: 

the demand for new products and services remains high 

which is also demonstrated by the large number of exhibitors. 

At the moment the organizer is already expecting over 440 

companies at FILTECH 2023 – more than ever before. 


news & facts 

Personal exchange at the heart of the congress 

Traditionally the FILTECH exhibition area is also complemented 

by a strong congress. Visitors thus not only 

have the opportunity to experience current products and 

services live but are informed about trends in research and 

development in the congress area. The FILTECH scientific 

advisory board, chaired by Dr. Harald Anlauf (KIT) and Prof. 

Eberhard Schmidt (Bergische Universität Wuppertal), guarantees 

the high quality of the presentations: experts from 

international universities, research institutions and companies 

review the submitted contribution proposals and compile 

a program that guarantees valuable information from all 

areas of the industry. The organizer expects more than 200 

presentations for FILTECH 2023. The congress at the event is 

divided into units covering all relevant topics. 

Seven thematic areas will be in focus: 

➢ solid-liquid separation 

➢ solid-gas separation 

➢ filter media 

➢ testing, instrumentation and control 

➢ simulation and modeling 

➢ product related processes 

➢ membrane processes 

In addition, the congress at FILTECH 2023 will be dedicated 

to current industry trends such as selective separation, micro 

process technology, and nanofluidics, mist and droplet separation 

as well as biological exhaust gas cleaning with biofilters. 

On February 13, 2023, already one day before the opening 

of the exhibition area, two focused one-day courses will 

be held, which will also specifically address engineers, scientists, 

managers, and other technical personnel who are interested 

in knowledge on topics related to solid-liquid separation 

and fine particle separation. 

Filtration processes for quality and reliability 

High dust levels, explosive dusts and pollutants endanger 

people, the environment and the plant. Filter solutions 

specifically designed for the harsh environments of processing 

prevent hazards to operators and the environment, increasing 

service life of the plant and equipment, ensuring 

high performance. 

At FILTECH processing companies will find the right 

products and services for this purpose and can exchange 

information with experts on current trends. For successful 

planning of the visit, interested parties can find a list of 

exhibitors, an overview of focus topics and industries as well 

as the extensive conference program at filtech.de. 

further information: www.filtech.de 

Topics for the future bear first fruits 

In light of the current global economic and political 

developments and challenges that come with them, 

MAPAL is working hard on future developments. 

MAPAL’s traditional main market, the automotive industry, 

remains a key pillar of its market strategy. With the addition 

of the future field of electric mobility, MAPAL solutions 

will be found in all areas of mobility. This also includes tool 

solutions for internal combustion engines until they are permanently 

discontinued. “Of course we also want to considerably 

strengthen our position in sub-segments other than 

power trains, for example with chassis and brakes,” explains 

Dr Jochen Kress, president of the MAPAL Group. The market 

segments of aerospace, fluid power technology and the die & 

mould sector are also in focus. MAPAL has gained a strong 

foothold in fluid power technology with intelligent solutions. 

The market strategy for the die & mould sector has now been 

rolled out worldwide. The necessary stock availability of tools 

is in place and structures are set up accordingly. Dr Kress 

explains: “We’re looking forward to the future with great 

optimism.” Across all segments, the machining of titanium 

and aluminium plays an important role in the market and 

product portfolio. 

The development and sales strategy aimed resolutely at the 

focus markets already began to bear fruit in the 2021 financial 

year: Group turnover rose to € 524 million, an increase of 

15 %. For the current year 2022 ongoing developments make 

it very difficult to make a reliable forecast. “The fact that our 

future developments are beginning to bear fruit is cause for 

optimism. The first six months of 2022 went well and according 

to plan.” 

The production area of the Altenstadt site was doubled 

thanks to the latest expansion 

Senior management is also looking beyond the current 

situation and investing in several sites worldwide. For example, 

completion of the construction work at the Altenstadt site 

means an increase in production space at the Center of Competence 

for solid carbide tools of 5,000 m 2 , improving the 

company’s ability to react in the competitive market significantly. 

Also in Poland substantial investments are being 

made. In India the construction project has been completed. 

Here a brand-new production and administration building 

was built, meeting the latest ecological standards. 

further information: www.mapal.com 


23

news & facts 

fairs 

Manufacturing community reconnected at IMTS 2022 

With handshakes, hugs, high-fives and hearty backslaps, 

as people greeted each other after four years, the 

connectedness of the manufacturing community was 

the literal showstopper at IMTS – The International 

Manufacturing Technology Show. 

Held September 12-17 at Chicago’s McCormick Place, IMTS 

2022 achieved a total registration of 86,307, including 11,715 

students and featured 1,212,806 million ft 2 of exhibit space 

representing 1,816 exhibitors and 1,603 booths. The North 

American visitor-to-exhibitor ratio increased by more than 

10 % compared to 2018’s record-breaking show, reaffirming 

the need to meet in person. 

“While the excitement and electricity were clearly evident 

in every aisle of the show, what was most gratifying for the 

industry and the country was the scope of commerce taking 

place as visitors sought out, and found, key technologies and 

productivity solutions to move their businesses forward,” says 

Douglas K. Woods, president of AMT – The Association For 

Manufacturing Technology, which owns and produces IMTS. 

“The digital technologies and other new products at this 

show aren’t just advanced: they are accessible, inclusive, and 

ready to be implemented by small and medium-sized businesses 

regardless of their workforce composition”, adds Peter 

R. Eelman, chief experience officer at AMT. 

“With the number of innovative products hitting the 

market now – cutting across the entire swath of automation 

and digital technologies that change the way we manufacture 

parts – we’re in a period of time that will not be paralleled 

again for decades” notes David Burns, principal and founder 

at Global Business Advisory Services. Burns points out that 

manufacturing technology orders per sale continued to increase 

from 2019 through 2022 and that they will continue to 

accelerate as companies use technology to compensate for a 

smaller labor force. 

The AM4U Area, presented by Formnext, a new venue 

for IMTS, featured well-attended daily presentations such 

as a panel of nine additive manufacturing experts discussing 

the benefits and drawbacks of various AM technologies. 

Formnext is the leading industry expo platform for additive 

manufacturing and industrial 3D printing. 

AMT and Gardner Business Media have collaborated with 

Mesago, the organizers of Formnext, and Messe Frankfurt 

Inc. to launch Formnext forum Austin (Aug. 28-30, 2023), 

the Formnext forum co-located at IMTS 2024, and Formnext 

Chicago (April 8-10, 2025) at McCormick Place. 

Automation 

After the human connection, IMTS 2022 will be remembered 

as the show of a thousand robots. Exhibitors integrated 

robots, cobots, and other automated functions to machining 

centers, welding systems, tooling centers, workholding pallets, 

inspection systems, and more. 

“The automation systems at IMTS focused on ease-of-deployment, 

iPhone-level programming simplicity, and affordability 

for small and medium-sized businesses,” says Tim 

Shinbara, chief technology officer at AMT. “Visitors could 

find new startup automation companies and spinoffs in every 

hall, and every one of them introduced solutions for highmix, 

low-volume applications to help job shops address their 

workforce and productivity issues.” 

Automation solutions at IMTS 2022 also combined the 

flexibility of a collaborative robot (cobot) with an autonomous 

vehicle that can drive around a shop and tend multiple 

machines without human intervention. Two exhibitors had 

eye-catching demonstrations of this technology. Staubli 

Robotics introduced the new HelMo mobile robot system, 

equipped with multi couplings, a tool-changing system, and a 

tool station. Nachi Robotic Systems demonstrated a CZ10 cobot 

arm mounted on an EffiBOT autonomous mobile robot 

simulating machine tending work. 

further information: www.imts.com 


news & facts 

Ambitious sustainability strategy 

“CO 2 

neutral” by 2025, “net zero” by 2040 

CERATIZIT presented an ambitious sustainability 

strategy on the occasion of AMB 2022 in Stuttgart. 

With the help of this strategy the company aims to 

become the leader in sustainability for the hard metal 

and cutting tool industry by 2025. 

Executive Board Member Thierry Wolter announced the 

ambitious sustainability goals, which will affect and change 

the entire supply chain, at AMB in Stuttgart. “Climate change 

is one of the greatest challenges of our time and requires the 

industry to rethink in many areas as well,” said Wolter. For 

CERATIZIT customers to also be able to produce more sustainably, 

the company has set itself ambitious targets for its 

own products and services. “Our vision is to be the leader 

in sustainability in the hard metal and cutting tool industry 

by 2025,” Wolter continues. 

Sustainability along the entire value chain 

In order to become sustainable throughout the company, 

CERATIZIT will look in future at the entire value chain with 

regard to environmental, social and governance criteria, ESG 

for short, and also include its cooperation with partners. In 

the first phase the focus will be on those aspects that have the 

greatest leverage effect. 

Reduction of the carbon footprint 

In order to drastically reduce its own carbon footprint quickly, 

CERATIZIT is initially focusing on three major levers. A 

decisive factor is the increase in the use of secondary raw 

materials to over 95 %. Compared to primary raw materials 

from ore, their processing requires 70 % less energy and 

reduces CO 2 

emissions by 40 %. A positive side effect is the 

safeguarding of the supply chain for raw materials, so that 

both the customers and CERATIZIT benefit twice. 

Another focus is on the power supply. CERATIZIT plans to 

switch the power supply of all sites to green electricity from 

wind, solar and water power in the next few years. 

Closely related to the change in power supply is the issue 

of hydrogen supply. It is needed as a production medium in 

the hard metal industry, especially for the production of tungsten 

powder. Up to now this hydrogen has mainly been obtained 

from natural gas by steam reforming, so-called “grey” 

hydrogen. For the future CERATIZIT plans to use “blue” hydrogen, 

which is produced from water by electrolysis with 

green electricity. For this purpose, CERATIZIT will cooperate 

with its existing suppliers and also build its own electrolysis 

plants. 

First milestone: CO 2 

neutral by 2025 

The first milestone in the implementation of the new 

strategy is 2025, by which time CERATIZIT plans not only 

to be CO 2 

neutral, i.e. to offset all emissions along the entire 

supply chain. The goal is also to reduce the actual emissions 

by 35 % compared to the reference year 2020. The 

second stage, 2030, envisages a reduction of 60 % compared 

to 2020 with the help of further measures. 

The most ambitious goal, however, is to achieve “net zero” 

by 2040 – a target envisaged by the Paris Climate Agreement 

only for 2050. “Reducing CO 2 

emissions along the entire 

value chain by at least 75 % by 2040 is without question a 

challenge. However, with a view to future generations we 

see no alternative to this path and are pleased to also let our 

customers participate in this through products such as our 

“GreenCarbide” rods, our award-winning SilverLine milling 

cutter with sustainability formula as well as a wide range of 

services,” Wolter explains the company’s motivation. 



25

news & facts 

LACH DIAMANT – 100 Years 

Tradition. Passion. Innovation 

part 3: 

From natural diamonds to synthetic diamonds 

“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, the video can be viewed at: 

https://bit.ly/LACHDIAMANT 

1957 was not only the year of the first signalling satellite 

“Sputnik” orbiting the earth. It was also the year which 

would propel the company LACH DIAMANT, Jakob Lach 

GmbH & Co. KG, to new heights – something no one at 

LACH could have foreseen at the time. The reason being that, 

in 1957, an American manufacturer named General Electric 

was the first to offer synthetically produced diamonds, socalled 

man-made diamonds, to the industry. More precisely, 

it was a developer of super abrasive materials, which would 

later set up shop in Worthington, Ohio, under the umbrella 

of GE Light Bulbs. From today’s perspective this could be defined 

as a mile stone for the beginning of the “diamond age” 

in our modern industry. For the first customers or users of 

this material, synthetic diamond grains, it was “only” an opportunity 

to switch from one natural material to a synthetic 

alternative. The application was predominantly as polishing 

Company founder Jakob Lach, 1894-1984 

(photo taken in 1980) 

and lapping grain, used in metal-bond bronze grinding 

wheels and in resin (rubber)-bond grinding wheels which 

were still in development at the time. The first synthetic 

diamonds could influence the development of carbide or 

carbide tools only insignificantly. The reason being that these 

grains lacked the ability to anchor themselves to the resin 

bond in order to provide the necessary chip spaces for pregrinding. 

This requirement would only be solved ten years 

later by ASEA, Friedberg, in Hessen, through the develop - 

ment of a procedure for the metal-coating of synthetic diamond 

grains. 

With this coating the plastic binder could now tightly 

attach to the metal-coated diamond. The diamond was now 

usable for up to 85 % until breaking out of the binder, even 

when pre-grinding carbides. More about that later. 

Diamonds as tools 

When I, Horst Lach, started in my father’s company on 

October 1 st , 1960, after completing my education as an industrial 

management assistant, I was “learning by doing” how 

diamonds could be used as tools. At that time there was absolutely 

no literature available on the use of diamond tools, 

with the exception of an occasional company brochure or 

some war-time research on the manufacturing of sintered 

multi-grain diamond dressing tools, so that even the smallest 

remnants of used single-grain diamonds could still be used 

for dressing grinding wheels. 

At universities and at other educational facilities the topic 

of “Using Diamonds for Efficient Production” was, if at all, 

underrepresented; this would change only within the last 25 

years. 

Even today, this information board on the correct handling of 

single point diamond dressers should be displayed 

in every training workshop. 

In the 1950’s, Jakob Lach had already established the basis 

for the enterprise I found in 1960: industrial diamonds were 

used for dressing grinding wheels in the ball bearing, anti- 


news & facts 

Jakob Lach congratulates Kurt Wagner, manager of the diamond 

cutting shop, on his birthday; right side Willi Reusswig (photo taken 

around 1965 in the Hanau facility at Bruchköbeler Landstrasse) 

A view into a natural diamond cutting shop, servicing single 

dressing diamonds and profile diamonds as well as 

natural diamonds (photo taken around 1967) 

friction bearing, electrical and the mechanical engineering 

industries as well as by crankshaft cylinder grinding shops. 

Contrary to today, back then customers were presented with 

a selection of loose diamonds (raw diamonds) from larger 

batches, and they could select the diamonds based on their 

own personal preferences. The customers themselves would 

then set the diamonds in holders. Fortunately for us, there 

was one exception among the high-volume customers, drive 

shaft manufacturer Lohr & Bromkamp GmbH in Offenbach, 

today known as GKN. For this particular company we kept 

a permanent on-call stock of set diamonds for morse tapers 

0 and 1, in top-notch quality between 1.5 and 2.3 ct, with a 

monthly order rate of 10 to 20 pieces. Profile cut diamonds, 

2-2.5 ct for MSO machines, would soon be added. 

Early marketing 

Decades of a good cooperation with this customer proved to 

be a model case for the positive future development of LACH 

DIAMANT as it was now called. During my apprenticeship 

at the end of the 1950’s, after I was confronted with the concept 

and basics of “marketing” by my boss, and after I was 

entrusted with “introducing marketing” in two facilities, it 

also had a high priority for me at LACH DIAMANT. It might 

be interesting to some of the readers, which marketing tools 

were available in those days. 

– for the acquisition of potential customers: 

various address books, ranging from the “ABC of 

German economy” to telephone or later telex directories 

– for the evaluation of potential customers: 

sales estimates/account cards from our own accounting 

department/credit agencies 

– initial contact was made via: 

telephone, telex, postal mail, advertisements, 

personal visits 

In other words very tedious and time-consuming work. 

Potential market companions with a conventional “diamond 

background” (diamond cutting shop or diamond retailer) 

were noted in our “marketing file”, such as Winter & Son in 

Hamburg, Urbanek in Frankfurt and Dürr in Cologne. A new 

company logo was designed, showing a symbolized holder 

with a set octahedron diamond in an inclined dressing position 

(as seen on the information board which was used until 

the year 2000). 

Demand for new services 

A growing demand from the cutting shops for more and 

more consistent precision required the use of single point 

dressing diamonds and thus also created the wish for a fast 

repair service. Depending on the quality, set octahedron 

diamonds show up to six suitable tips for dressing; when they 

are no longer usable for the desired results, the diamond has 

to be removed from its holder or be reset to the next useable 

Synthetic man-made diamond grains for resin-bond diamond 

grinding wheels – left with metal coating – right without 

metal coating (state of development from around 1968). 


27

news & facts 

Doctor Fritsch, owner of the company with the same name, 

personally operates the first diamond grinding wheel press – 

a press sintering machine 

(photo taken around 1963) 

tip. When all tips are worn, a diamond cutter can resharpen 

the natural diamond and create a new tip. This was the result 

of a first study on the topic “Fast service for repairing single 

diamonds”. 

The “Express LACH Repair Service” was born – re-setting 

within 24 hours. The first marketing success, and executed 

accordingly, except for the fact that, due to our own production 

capacity limitations, this work was first carried out by 

a partner company until it became too much for them. Any 

way, it was a good thing. My father and I decided to offer this 

service internally again. It was the start for our own diamond 

tool production. 

Diamond tools, made at LACH 

Diamond cutters were employed again, among them experienced 

cutters like Kurt Wagner and Willi Reusswig; both had 

received excellent training at a well-known manufacturer of 

turning diamonds for the watch- and clock-making industry 

in Switzerland. Gradually the necessary machines were 

purchased. Among them the first press sintering machine 

for the production of metal-bond diamond grinding wheels 

and multi-grain dressers, personally put into operation by the 

developer Dr. Fritsch in 1962/63. 

Thanks to Kurt Wagner’s know-how as manager of the diamond 

cutting shop with approximately 20 workers, they succeeded 

in winning Bosch-Bühlertal as customer for the production 

and service of the necessary turning diamonds for 

overturning the copper commutators produced there. Word 

got around. From then on even commutator manufacturers 

such as AEG and Siemens were among our customers. The 

young production team grew day by day, proud of the problems 

solved. 

At the beginning of the 1960’s my father and I began to take 

turns in presenting raw products to customers; if I remember 

correctly, we were travelling at times with materials insured 

up to 1 million DM. Jakob Lach was still personally in charge 

At Hanover trade show in 1968, and to an astonished audience 

of experts, Karl Ruth demonstrates cutting with a newlydeveloped 

resin-bond diamond grinding wheel (K-MC bond) 

with a metal-coated diamond grain on a 

Simon steel grinding machine 

of purchasing the diamonds in Antwerp/Belgium. At the 

beginning of the 1960’s, an external employee assisted with 

sales. Otto Lang had started as an independent sales represenative 

around the same time as I had. He travelled weekly 

from his residence in Schorndorf to Baden-Württemberg. 

He left at 6 am on Mondays, returning on Fridays with a 

full order book. On Saturdays his wife completed the results 

of his long trips with visit reports and mailed them at 

the post office. On Sundays between 11 and 12 am, we took 

turns picking up the already sorted Saturday mail from our 

lock box at the main post office in Hanau. And of course 

father and son took a first look at the visit reports and orders. 

In case of orders for single dressing diamonds, my father 

did not let himself be deterred from immediately starting to 

process the order by selecting suitable “stones” and preparing 

the order for fulfillment on the following Monday. The Lang 

couple became good friends of our family, especially since 

they later became the godparents for my son Robert. 

In the 1960’s, sales representatives were also added in Bavaria 

(Nuremberg) and North Rhine-Westphalia (Düsseldorf), in 

addition to Baden-Württemberg. 

Increased monthly sales 

Monthly sales increased. In the beginning, I had kept track 

of the rising curve on graph paper. However, after I had to 

attach three to four new sheets for extending the curve, I 

surrendered and observed future trends solely based on the 

account sheets of the accounting department. 

During the early 1960’s you did not have to analyse the 

numbers in detail to see that turnover originated mainly 

from sales of industrial diamonds or dressing tools respectively. 

However, due to increased activities of our sales representatives, 

we now also received delivery inquiries for diamond 

grinding wheels for glass (lead crystal) and carbide 

machining. Our previously mentioned market companions in 

Hamburg and Frankfurt offered us a resale discount of 10 % 

on inquiries for diamond grinding wheels – not enough for 


news & facts 

received my first hints and tips from a lab manager at 

Bakelite company. But as an industrial business management 

assistant I must have confused some of the instructional 

details. He talked about aluminium oxide as a filling 

agent, and I thought it was aluminium powder. When the somanu 

factured test wheels came into operation on a Finimat 

carbide tool sharpening machines, developed by engineer 

Erwin Vollmer in Dornhan, people were very enthused about 

the number of teeth registered by an automated counter; 

the coating, “shining with power”, hardly showed any wear. 

Even years later, sales representatives did not quite know how 

to deal with frequently incoming reorders. 

A view into part of the diamond wheel production 

in the mid-sixties: Ute Kiesel and Karl Ruth in the process 

of filling wheel forms 

Then, finally – 1966/67 – the previously repeatedly mentioned 

metal coating for synthetic diamonds became reality 

in the form of the de Beers Kornes RDA-MC (MC standing 

for metal coating). Developed by the company ASEA, bought 

out and patented by de Beers. This meant for General Electric 

that they had to pay a license fee of 5 cents to de Beers for 

every sold carat of the diamond grain with metal coating. 

business operations and commissions for our sales representatives. 

After installing a pressure sintering machine, we had 

fewer problems with metal-bond grinding wheels; we could 

do our own calculations based on the required diamond 

content. 

In those years, the wheels which we already manufactured 

in-house, were mostly sold to manufacturers of lead crystal, 

such as the company Nachtmann, Peil and Putzler which had 

invested in new grinding machines, e.g. Kutscher machines. 

Attempts to enter the market for eyewear failed due to prevailing 

price demands. 

After making the first wheel for ceramics for Feldmühle, 

Plochingen (with dimensions of 400 x 200 mm width and 

one (!) mm layer depth) and resulting, to the great dismay of 

Dr. Fritsch, in the transformer of the sintering machine 

going up in flames, we left this particular market segment for 

the time being. 

Resin-bond diamond grinding wheels 

Our lack of a competitive edge and the general topic of resinbond 

diamond grinding wheels remained a topic of great interest 

to us. Attempts to procure such wheels from newly 

emerged manufacturers in France and the Netherlands were 

not that successful. Reasons for failure were the lengthy and 

tedious communication (via telex), as well as delivery times 

and, most annoying to us, the lack of consensus on determining 

the respective diamond content of each wheel. The latter 

was even in the 1960’s a significant factor for comparing 

prices and bids. The exact diamond content had to be noted 

depending on the concentration (for example, concentration 

in percent by volume C = 100 = 4.4 ct per cm 3 ). 

What to do? Manufacture in-house? But where would the 

know-how come from? It was 1964/65. As I mentioned earlier, 

literature was scarce on the subject, even the first usable 

plastics were sold as “secret recipes”. Not to mention 

mixing proportions for filling agents or compounds. I 

During the boom of the 60’s: 

metal-bond diamond grinding wheels for automated cutting 

of crystal glasses on Kutscher machines. 


29

news & facts 

I claim that this idea of coating synthetic 

diamond grains with a spattered 

metal coating (which allows for 

the resin to tightly latch onto its “coral-like” 

surface), was solely responsible 

for the boom-like success of 

carbide in the tool industry, and of 

course for the success of the resinbond 

diamond grinding wheel. Finally, 

the prevailing school of thought 

that diamond grinding wheels could 

only be used for lappers and polishers 

of carbide, could be successfully 

refuted. The now available metalcoated 

diamond grains allowed for 

pre-grind ing and even deep grinding 

operations with resin-bond 

wheels. Especially manufacturers of 

wood machining tools, such as Ledermann, 

Leitz and Guhdo, as well as 

the machine manufacturers for these 

tools, such as the companies Vollmer 

in Dornhan and Biberach, and for 

example Stehle and Kuhlmann, 

would profit the most in this period 

of prosperity. To name a few representatives for metal tool 

manufacturers, the companies Walter, Carboloy/USA and 

Sandvik/Sweden can be listed. Among the many precision 

machine manufacturers that now distinguished themselves 

on the market, Jung (flat grinding machines) and PTW (optical 

profile grinding machines) remain as outstanding companies 

in my memory. 

Ad hoc, the metal-coated diamond would influence the 

further development of LACH DIAMANT as well. “MC” 

(metal-coated diamond) was added to the “K” (Kunststoff – 

the German word for plastic), as K-MC (representing resinbond 

LACH DIAMANT grinding wheels with metalcoated 

synthetic diamond grains). With the new K-MC 

LACH DIAMANT first time at Hanover trade show 1967, being co-exhibitor from 

Hofmann & Co. Maulbronn; from left to right: Kurt Wagner, Karl Ruth, Horst Lach, 

Otto Lang and as special guest figure skater Matzdorf 

grinding wheel we were able to win the company Simon in 

Neu-Isenburg as our biggest new customer as their machine 

supplier for the double-tool-grinding machine L15 for lapping 

and tension grinding of soldered carbide steels; at that 

time we already supplied the also needed metal-bond flute 

grinding wheels. In the meantime a lot of other developments 

had happened at LACH DIAMANT. We had indeed 

succeeded in gaining much-sought after admission to the 

spring trade show in Hanover. We were co-exhibitors with 

Hoffmann & Co, Maulbronn. When they were looking for 

a mechanic to demonstrate the use of a deburring tool for 

auto bodies we stepped in. In return they allowed us to give a 

demonstration with the new K-MC diamond grinding wheels 

on the previously mentioned Simon steel grinding machine. 

Bad luck for our endeavour to show off a new deburring tool. 

Unfortunately the demonstration of the “deburring process” 

on the sheet metal auto body proved to be so annoyingly loud 

that all exhibitors from hall 7 voted unanimously to stop 

this presentation at that time. However, it was a trade show 

debut for LACH DIAMANT. At the very next trade show 

we already had our own stand. By the way, at approximately 

the same time LACH DIAMANT became a member of FWI, 

the professional association of the tool industry, section 

diamond tools. 

LACH DIAMANT at Hanover trade show, spring 1968, for the 

first time with our own booth; featured diamond tools were 

dressing tools, natural turning diamonds, resin- and metalbond 

diamond grinding wheels, diamond pastes and the spray 

MF programme; in the center Kurt Wagner (left) in 

conversation with Jakob Lach. 

My father, being then almost 75 years, who also noticed 

the positive development of our company, then gave the goahead 

for major extensions of the natural diamond cutting 

shop which later became the location of the diamond wheel 

production facility and sintering technology. 

A good and wise decision, as you, my dear readers, will be 

able to confirm after the next report that begins with the year 

of 1969. 

Your Horst Lach 

further information: www.lach-diamant.de 


news & facts 

Four generations and 100 years in metal cutting 

Preben’s grandfather, 

Louis Eckart Hansen 

In a world where 

machine shops are 

struggling to stay 

open and maintain 

their business 

and “going into 

dad’s business” is 

not what it once was, 

Platinum Tooling 

is an exception to 

the rule. Located in 

Prospect Heights, 

Illinois, the company 

is set to reach an important 

milestone. In 

2022, company president 

Preben Hansen 

and his family will 

celebrate 100 years 

working in metal cutting 

and four generations 

of Hansen men 

in the industry. How 

cool is that? 

The story began with Preben’s grandfather, Louis Eckart Hansen, 

who learned his trade in Copenhagen, Denmark in the 

early 1900’s. Louis worked as a machinist in the Danish Navy’s 

repair facility. Preben’s father, Svend Eckart Hansen, 

honed his skills under the guidance of Louis. 1958 Svend emi - 

grated to the U.S.A., with his family including young Preben. 

Despite not knowing English, he found employment within 

days of arriving in Chicago, because of his skill as a tool 

maker. Svend began his career as a machinist and ended it 

in the 1990’s as a master tool maker at Ramcel Precision 

Stamping and Manufacturing LLC in Northbrook, Illinois. 

With manufacturing and tooling in his DNA, Preben 

worked in the machine shop of the former Fulton Machine 

Company in downtown Chicago, while attending the University 

of Illinois/Chicago and pursuing a degree in engineering. 

After college he worked in the shop at Oakley Industries 

building custom machinery. After several years there Preben 

moved to the front office and to an inside sales position. 

Preben with his dad, Svend Eckart Hansen 

Later, at Jemco Tool & Die, he learned programming and setup 

on their CNC lathes and machining centers which was his 

introduction to machine tools and their accessories. His next 

job was at HPI, now known as Pioneer Heartech Precision 

Inc., a distributor of tool holders and related products, in 

Elk Grove Village, Illinois. Preben started as an outside sales 

repre sentative of tool holders and rotary tables, then became 

the company’s sales manager. This was followed by 

Lyndex-Nikken, another machine tool accessory supplier in 

Mundelein, Illinois. Preben was introduced to live tools and 

once again worked as sales manager. In 2010, Preben started 

a joint venture with heimatec GmbH, becoming the president 

of Heimatec, Inc., a company specializing in live tools, 

angle heads and multispindle drill heads. 2018 Heimatec, Inc. 

was purchased by Platinum Tooling Technologies, Inc. with 

headquarters located in Prospect Heights, Illinois. Preben 

Hansen is the COO and president at Platinum Tooling. 

Preben has over 30 years of experience in the machine tool 

accessory market and over 40 years in the manufacturing industry. 

Given his credentials, it’s no surprise that Preben has 

established himself as a leading authority on these topics in 

the North American machine tool accessory market. He often 

hosts knowledge bars at trade shows to SRO crowds. 

Preben Eckart Hansen and his son Luke James Hansen 

In keeping the family tradition, Preben’s son, Luke Hansen, 

joined his dad’s company in 2018 as a technical sales specialist 

for several of the product lines sold by Platinum Tooling, 

including Tecnicrafts collets and guide bushings for Swiss 

machines. After graduating from high school Luke joined the 

army and received great training there. Upon his discharge, 

he used the motivational and goal orientation skills he had 

learned in the army. In his current position at Platinum 

Tooling Luke continues to expand his knowledge of the 

machine tool accessory market as well as builds valuable 

relationships with the North American sales and distribution 

network of the company. 

Reflecting on 100 years as a family in the manufacturing 

industry, Preben Hansen says, “The machine tool industry 

has been and continues to be an extremely vital part of our 

country’s continued success. My son Luke and I are proud 

to be 3 rd and 4 th generation professionals involved in this 

exciting industry.” 

further information: www.platinumtooling.com 


31

processes 

Retrofit unit for cryogenic process cooling 

written by 

Thomas Götz and Andreas Gebhardt, 

Fraunhofer Institute for Manufacturing Engineering and Automation IPA 

The use of carbon dioxide as a cooling medium can 

significantly improve the economic efficiency of machining. 

For the simple retrofitting of cryogenic cooling 

technology in existing machines, MHT GmbH Merz & 

Haag and Fraunhofer IPA have developed and successfully 

tested a new solution. 

In the machining process, tool and workpiece are subjected 

to high mechanical loads, whereby the mechanical energy applied 

for chip formation is almost entirely converted into heat 

in the shear and friction zone (figure 1). Only about 75 % of 

the resulting heat flows are dissi pated with the chip, while the 

remaining approx. 25 % are introduced into the cutting tool 

or the workpiece. On the one hand, this thermal load leads to 

an intense heating of the workpieces, which is associated with 

a corresponding expansion of the latter. In addition, the high 

temperatures cause signs of wear on the cutting tool, such as 

mechanical abrasion, diffusion processes or scaling. These 

effects have a negative impact on the machining quality 

and machining accu racy of the workpieces as well as the tool 

life. (Klocke und König 2008; Lang 2012) 

Cooling strategies in machining technology 

Cooling lubricants are typically used to avoid or reduce a 

temperature load in the machining process whereby cutting 

tools and workpiece are usually flooded with the cooling 

lubricants. This cooling strategy, known as wet machining, 

does not only allow the removal of the process heat from the 

tool-workpiece contact point by cooling, but also a reduction 

of frictional heat by lubrication. Cooling lubricants thus 

contribute to a high level of performance in a wide range of 

machining processes. (Lang 2012) 

Alongside the technological advantages associated with 

the use of cooling lubricants, however, they pose a not insignificant 

risk to people and the environment. For example, 

cooling lubricant components such as bactericides and fungicides 

can trigger illnesses in the event of contact or aspiration. 

In addition, leakage and drag-out losses, washing 

water or the disposal of used cooling lubricants lead to pollution 

of soil, water and air. Legislators have therefore imposed 

strict regulations on the handling and disposal of cooling 

lubricants. For the industry, these requirements involve, 

apart from a high level of responsibility towards their employees, 

a high financial burden as well (e.g. disposal costs). 

(Klocke und König 2008; Koch 2015) 

One approach to completely avoid the use of cooling lubricants 

is the so-called dry machining, in which either limited 

air cooling is realized or completely without cooling. In dry 

machining, the coatings of the used cutting tools are therefore 

of particular importance, with the aid of which the thermal 

load on the cutting materials is to be reduced and adhesion 

and friction processes between the cutting tool and the workpiece 

are to be reduced, too. Disadvantages of dry machining 

include, among others, higher heat generation in the process, 

which can have a negative effect on dimensional accuracy, 

and the elimination of chip removal by cooling lubricants. 

If the lubricating effect of cooling lubricants cannot be completely 

dispensed with, minimum quantity lubrication can 

also be used during machining. With this cooling method, 

an aerosol of air and lubricant is fed to the cutting point. 

(Lang 2012) 

figure 1: 

Energy conversion and heat during machining 

(Kühn et al. 2018) 

Another alternative to conventional cooling lubrication 

concepts is cryogenic process cooling (figure 2). Here, media 

with extremely low temperatures are used for cooling. Typical 

cryogenic media are liquefied gases such as hydrogen 

(boiling point 20.268 K = -252.882° C) and nitrogen (boiling 

point 77.35 K = -195.80°C), but also carbon dioxide snow (sublimation 

point 194.5 K = -78.5°C). (Klocke 2017) 


processes 

Major drawbacks of using hydrogen and 

nitrogen in machining are the complex 

storage, feeding and insulation technology. 

For example, liquid nitrogen boils under 

atmospheric pressure, which is why 

vacuum-insulated containers must be 

used for storage. (Klocke 2017; Awiszus et 

al. 2020) 

In comparison, carbon dioxide (CO 2 

) is 

much easier to handle as a cooling medium 

because CO 2 

is in liquid form at room temperature 

and under high pressures. This 

property allows the liquid CO 2 

to be fed 

through a pipeline to the machining site 

under a pressure of 6MPa without insulation. 

(Klocke 2017; Awiszus et al. 2020) 

At the time of discharge, an abrupt pressure 

drop affects the liquid CO 2 

, which 

subsequently expands to a mixture of 

solid (45 %) and gaseous (55 %) states. The 

solid phase of the mixture is also referred 

to as dry ice and has a significantly higher 

cooling capacity as compared to the gaseous 

phase. (Klocke 2017) 

The carbon dioxide does not form harmful 

vapors and mists that can be inhaled 

with the air, so there is no health risk for 

the operator. Also, the cleaning of the 

workpieces or the disposal of the chips is 

simple. The workpieces remain dry and are 

not contaminated with oils and greases, 

which means that a final cleaning of the 

workpieces is largely unnecessary. 

figure 2: 

Cooling lubrication processes in machining production 

(after Lang 2012) 

Systems currently available on the market for cryogenic internal cooling use 

the concept of feeding the cooling medium through the motor spindle by means 

of a rotary feedthrough. However, this concept is associated with an increased 

risk of unwanted cooling of machine components, which in turn can lead to 

inaccuracies in the production or greater wear. In addition, the required 

modification of the motor spindle is complex and cost-intensive. (Volz und 

Abele 2019) 

Feeding strategies of 

cryogenic cooling 

In the case of cryogenic feeding strategies, 

a fundamental distinction can be made 

between cryogenic flood cooling and cryogenic 

internal cooling (figure 3). 

In cryogenic flood cooling, the machining 

point is flooded with the cryogenic cooling 

medium from the outside. Although 

this feeding strategy is simple to implement, 

it is also associated with some disadvantages. 

On the one hand, the cooling 

medium does not reach the cutting edge of 

the tool sufficiently, and on the other hand, 

there is a high consumption of the cooling 

medium required. In comparison, cryogenic 

internal cooling achieves a significantly 

higher cooling capacity, since the 

cooling medium is fed directly to the machining 

point. In addition, the consumption 

of the cooling medium can be significantly 

reduced with this feeding strategy. 

(Lang 2012) 

figure 3: 

Feeding strategies of cryogenic cooling 

(Lang 2012) 

Retrofit unit for cryogenic cooling 

Due to the existing disadvantages of a coolant supply through the motor 

spindle, the use of the IKZ medium distributor of MHT GmbH for cryogenic 

machining using CO 2 

was investigated as part of a joint project between 

MHT GmbH Merz & Haag and the Fraunhofer Institute for Manufacturing 

Engineering and Automation IPA. The medium distributor is an independent 

system for internal cooling (IKZ), consisting of the components spindle attachment, 

IKM annular body and IKM tool holder (figure 4). The system is characterized 

by the fact that it can be retrofitted in existing machines at low cost and 

without great effort. 


33

processes 

figure 4: IKM- medium distributor 

Within the project, liquid CO 2 

was supplied from immersion 

tube bottles using a high-pressure hose via the spindle 

attachment, whereby the feed could be controlled via a solenoid 

valve, which was interposed immediately in front of 

the spindle attachment. 

As soon as the solenoid valve was opened, the liquid CO 2 

got into the internally cooled cutting tool via the interfaces 

on the ring body and the tool holder and expanded to CO 2 

snow when exiting the cooling channel. Extensive research 

has shown that the MHT system, which is actually designed 

for MQL or compressed air, also seems suitable for cryo genic 

cooling. 

A control system was also developed 

for actuating the solenoid valve, 

in which the feed is carried out via 

freely definable machine parameters. 

The machine parameters are provided 

by the machine control used, a Siemens 

Sinumerik 840d CNC control, via an 

OPC UA server, queried with the aid of 

the Node-RED development tool and 

transmitted as a trigger signal to an industrially 

suited, freely programmable 

PLC of the CONTROLLINO type. The 

PLC uses the trigger signals to open 

or close the solenoid valve so that the 

liquid CO 2 

can be fed to the machining 

point through the cooling channel 

of the cutting tool. In the future, 

the control system will make it possible 

to implement a speed-, tool- or 

material-dependent coolant supply. 

Summary and outlook 

Within the scope of the joint project, a retrofit unit based 

on MHT medium distribution for cryogenic process cooling 

was developed and successfully tested. Further future 

research is needed to observe the effects of the CO 2 

cooling 

medium on the tightness at the interfaces over a longer 

period of time. In addition, further extensive tests on cryogenic 

machining should be carried out. Here, the focus 

should be primarily on the evaluation of tool life and surface 

quality under variation of cutting tools, materials, contact 

widths, speeds as well as the CO 2 

volume flow. The knowl - 

edge gained from this should be used to implement an intelligent 

control system. 

Literature 

Awiszus, Birgit; Bast, Jürgen; Hänel, Thomas; 

Kusch, Mario (eds.) (2020) 

Grundlagen der Fertigungstechnik 

Carl Hanser Verlag. 7. fully revised and expanded edition. 

München: Hanser (Hanser eLibrary) 

Klocke, Fritz (2017) 

Fertigungsverfahren 1. 

Zerspanung mit geometrisch bestimmter Schneide 

Berlin: Springer Vieweg (VDI-Buch) 

Klocke, Fritz; König, Wilfried (2008) 

Drehen, Fräsen, Bohren 

8. edition [newly edited]. 

Berlin: Springer (VDI-Buch, volume 1) 

Koch, Thomas (2015) 

Mikrobiologie der Kühlschmierstoffe 

1. edition. Tübingen: expert verlag (series Technik). 

Available online: http: 

//nbn-resolving.org/urn:nbn:de:bsz:24-epflicht-1970406 

Kühn, Klaus-Dieter; Fritz, Alfred Herbert; 

Förster, Ralf; Hoffmeister, Hans-Werner (2018) 

Trennen 

In: Alfred Herbert Fritz (ed.): Fertigungstechnik. 

Berlin, Heidelberg: Springer Berlin Heidelberg 

(Springer-Lehrbuch), page 225 – 378 

Lang, Heiner (2012) 

Cryogenic – Zerspanen mit tiefkaltem Stickstoff 

available online: https://www.zukunftsorientiertezerspanung.de/leistungsspektrum/fachinformationendetailansicht/cryogenic-zerspanen-mit-tiefkaltemstickstoff.html 

Volz, Marcel; Abele, Eberhard (2019) 

Innovative Chuck with Integrated Rotary 

Feed-Through for Drilling Process with 

Application of Cryogenic Cooling 

In: Robert Schmitt und Günther Schuh (eds.): 

Advances in Production Research. 

Cham: Springer International Publishing, page 278 – 287 

further information: www.ipa.fraunhofer.de 


processes 

New standards for eroding 

The sharpening specialist VOLLMER has boosted 

its VHybrid 260 grinding and erosion machine, 

and now achieves a surface quality of 0.05 μm/Ra 

(micrometre/average roughness value) when eroding 

PCD tools (polycrystalline diamond). The process 

innovation succeeded thanks to the optimisation of 

the Vpulse EDM Generator. 

The optional V@ boost solution is designed for drills or 

milling cutters of a Ø of 1.0 mm. Such small PCD tools are 

mainly used in sectors such as automotive construction, 

medical engineering or the electronics and aerospace sectors. 

These days, PCD cutting tools are an essential component 

for many modern industrial manufacturing procedures. 

Thanks to their hardness and wear resistance, they are ideal 

for machining light metals, fibre composites, brittle-hard 

materials, as well as wood/wood composites. However, sharpening 

PCD tools is increasingly challenging even for experienced 

manufacturers. Especially if tools have to be ground or 

polished on various functional areas following erosive machining. 

For this purpose an additional work step is usually 

downstreamed, bringing with it an exacting process design. 

Generator with adaptive control 

The Biberach-based sharpening specialist VOLLMER has 

now succeeded in significantly improving this eroding process 

using their VHybrid 260 grinding and erosion machine 

in one set-up. Thanks to the new performance package for the 

Vpulse EDM generator, it is possible – for the first time – to 

reliably achieve a PCD tool surface quality of 0.05 μm/Ra 

(micrometre/average roughness value) in unmanned loader 

operation when eroding using the VHybrid 260. These 

values can be achieved thanks to the use of adaptive control 

technology together with the familiar innovative yet robust 

kinematics of the VHybrid 260 in combination with minimal 

discharge energy levels. This means that the finest of surfaces 

can be achieved. The savings in cost-intensive follow-up processes 

created by this provide the manufacturers of PCD tools 

with a profitable business, since they reduce the manufactur- 

100,0 μm 

1000,0 μm 

The size comparison with a matchstick shows how precisely 

the Vollmer VHybrid 260 with the new V@ boost solution 

can sharpen ultra-thin carbide tools 

ing costs per tool and increase the quality and durability for 

the end user. For the future it will also be possible to manufacture 

full-head PCD tools costefficiently in the smallest 

diameter ranges. 

The VHybrid 260 joined the party at AMB 

At AMB 2022, the metalworking trade show in Stuttgart, 

interested parties at the VOLLMER stand could watch how 

PCD tools are sharpened in one set-up with the VHybrid 260 

grinding and erosion machine. The visible result are the reflective 

surfaces, which are otherwise only possible with 

time-consuming and cost-intensive grinding work. Thanks 

to the V@ boost solution, it will be possible in future to 

integrate the erosion into the tool manufacture as a complete 

manufacturing process. Tool manufacturers can use 

the VHybrid 260 to machine as usual with reliable process 

management in an unmanned operation. 

Eroding and grinding up to 100 % each time 

In general the VHybrid 260 can be used to grind or erode 

both carbide and PCD tools up to 100 % in one set-up. The 

VHybrid 260 is based on multi-layer machining, which is 

implemented using two vertically arranged spindles. Here 

VOLLMER is using the tried-and-tested technology of its 

VGrind grinding machine series. With the VHybrid 260, the 

bottom spindle can be used both for grinding and for eroding, 

while the top spindle is reserved exclusively for grinding. 

The visible result of the new V@ boost solution for 

Vollmer’s VHybrid 260 machine is mirror-like surfaces 

on the cutting edges, previously only possible with 

complex and cost-intensive grinding operations 

Standard and special tools can be flexibly ground and 

eroded – regardless of whether the blanks consist of carbide, 

PCD or soldered PCD plates. The machine can be used for 

tools with Ø of up to 150 mm and lengths of up to 360 mm. 

The unmanned, round-the-clock machining allows for various 

automation solutions: meaning that the HC4 Plus chain 

magazine can hold up to 53 HSK tools, for example. In addition 

up to eight grinding and eroding wheels, including coolant 

supply, can be switched fully automatically. 

further information: www.vollmer-group.com 


35

processes 

Making industrial production more flexible, 

more productive, and more sustainable 

Maximum productivity and sustainability, 

with flexible machine solutions for 

many different production tasks and sectors 

– this summarizes best the EMAG 

Group’s focus for this year’s presence at 

AMB in Stuttgart. At the trade fair the specialists 

presented their technological scope, 

from turning, grinding, and hobbing 

to robot-based automation to laser and 

ECM machining. And data-based analysis 

and optimization of production process 

will continue to be a key focal point 

at EMAG. Accordingly, visitors got to 

see a range of IoT products that can, for 

example, reveal the energy consumption of 

a machine or its status. 

Under the name EDNA (short for “EMAG 

DNA”) the machine manufacturer has been advancing 

data-based networking of its production 

solutions since years. This makes it possible, 

for example, to determine the status and OEE 

values of a machine with great accuracy and get 

information on its current production output. 

At AMB EMAG presented the next IoT development 

step – an energy monitor with which an 

unusual high energy consumption (for example 

per workpiece) can be detected any time. “Sustainability 

through transparency,” is the motto. 

In these days, with the world facing a climate 

and a growing energy crisis, this is becoming increasingly 

important. 

Combination as the recipe for success 

The mechanical engineering solutions shown by 

EMAG are similarly efficient and sustainable. 

Electromobility in focus: visitors were shown a 

turnkey manufacturing line for rotor shafts and 

laser coating of innovative brake disks 

From the product range of EMAG Weiss, the 

W 11 CNC universal cylindrical grinder could be seen at AMB 

The SG 160 from EMAG SU is particularly impressive. It machines turn 

blanks in a completely dry process that combines hobbing and gear 

generating grinding in a single clamping operation. Subsequently these 

gears are nitrided and after the drilling work is completed, they are finished 

on a turning machine. This not only saves an enormous amount of 

space in the manufacturing hall, but also reduces the investment costs 

greatly, as this process would customarily require separate machines for 

hobbing and generating grinding respectively. Additionally, the process 

time is much shorter than when using individual processes, because 

both processes are fine-tuned to each other. The new machine makes use 

of two procedures on two different tool spindles: hobbing for the soft machining 

and dry generating grinding (finish grinding). A huge amount of 

electrical energy is saved in the manufacturing, since the alternative – wet 

grinding – always necessitates a filter system, cooling and oil mist extraction. 

These “energy guzzlers” are not necessary for dry machining with 

the SG 160. 

The VLC-GT series, presented by EMAG at AMB, offers a similar combined 

machining operation. With these machines different technologies 

such as hard turning, internal and external grinding, milling, reaming, or 

honing can be combined, and the machining in a single clamping operation 

ensures that the components are of high quality. Using the pick-up 

principle and combination machining, not only chucked components but 

also short shaft parts can be produced on the VLC 200 GT. 

Efficient machining of large components for 

commercial vehicles 

A literally large solution in the field of vertical turning is the VSC 500, 

which EMAG demonstrated live at the AMB – a platform for the production 

of large and very heavy workpieces, such as those found in the commercial 

vehicle sector, from brake drums, transmission and engine components 

to wheel hubs. These components undergo turning, drilling, sinking, 

reaming, milling, and threading processes in the very rigid machine, 

depending on the specific requirements. Even more productivity is guaranteed 

by the DUO variant for machining in two clamping operations 

(OP 10/OP 20). 


processes 

The new automation cells with robots ensure fast, 

cost-efficient, and reliable production processes; 

EMAG provides different configuration options: 

Automation cell with basket stacking: here the loading and 

unloading operations of the system make use of baskets from 

which the robot grabs the pre-aligned workpieces or deposits 

them; the empty baskets are placed onto a stack 

Bin-picking automation cell: the workpieces are in chaotic 

positions; with the aid of a 3D sensor system, the robot not 

only takes out the parts, but also correctly identifies, aligns 

and feeds them to the next machining step 

Automation cell with drawer system: the workpieces are 

provided on different levels; while the drawers are being filled, 

the robot supplies workpieces to the machine 

Making innovative new products possible 

An example of sustainable technology advanced by 

EMAG’s customers is electromobility, for which EMAG 

has provided many production solutions in the past years. 

At AMB the specialists presented some of these, for example 

a turnkey manufacturing line for a two-piece rotor 

shaft that is produced in a total of seven successive operations. 

Another technology of great interest within the context 

of sustainable products, is laser coating of brake discs 

with a machine from EMAG LaserTec, which can smoothly 

be integrated into complete production lines with upstream 

turning and downstream grinding processes. This 

makes it possible to create wear- and corrosion-free brake 

discs that produce less fine dust. Additionally EMAG 

LaserTec presented its new highly flexible ELC 1200 V 

machine platform, for individual applications from laser 

cleaning and laser welding to laser hardening. 

Large range of technologies 

The large range of technologies and applications mastered 

by the EMAG Group was showcased at AMB for example 

in the form of the W 11 CNC cylindrical grinder from 

EMAG Weiss, which enables extremely precise machining 

of individual parts, prototypes and small series, as well 

as the VTC 200 CD shaft turning machine, which features 

a center drive for simultaneous 4-axis machining with 

short cycle times. Additionally the K 160 hobbing machine 

demonstrated that EMAG’s range of effective production 

solutions is not limited to the automotive industry: 

the machine is ideal for small gearing up to module 2.5, 

such as those used in hand tools, for example cut-off saws. 

Electrochemical machining (ECM) also plays an important 

role in a wide variety of industrial sectors. EMAG’s 

specialists have created a solution for manufacturing 

complex internal geometries or internal gearing – and 

high-strength materials or large quantities are no problem 

at all. 

New automation cells 

Another focal point at EMAG’s trade fair booth was the 

topic of automation, because the machine manufacturer 

from the south of Germany has developed new automation 

cells with robots. The entire production process is getting 

faster, more cost-efficient and more reliable, with the 

pick-up technology from EMAG being particularly suitable 

for this approach as the machines have an internal 

automation system, which serves as a good basis for 

having them loaded and unloaded by robot solutions. 

The parts are, for example, fed pre-aligned in baskets or 

drawers, chaotically as bulk cutoffs or by means of infeed 

and outfeed conveyors. 

Currently an overall change in the production conditions 

of many companies is in progress: modern technology 

and changed applications increasingly lead to more 

complex components. Additionally the price pressure is 

getting stronger and the demands for energy-efficient 

processes are getting louder. EMAG demonstrated how 

these requirements can be met. 

further information: www.emag.com 


37


The leader in 

complete machining 

At AMB 2022 WFL Millturn Technologies presented 

the new M20 MILLTURN complete machining center 

for the first time. Alongside gear skiving technology, 

there is a clear trend toward automation and the 

integration of sensors. The latest solutions from WFL 

range from smart software to screw programming 

through to intelligent tools and clamping devices. 

WFL is the only manufacturer worldwide that concentrates 

exclusively on the production of multifunctional complete 

machining centers. In many high-tech companies today, the 

trade name MILLTURN stands for the central machine tool 

for the production of complex components with the highest 

precision. 

The M20-G showcased at AMB is equipped with an innovative 

automation solution – the intCELL. The integrated production 

cell is fitted on the right-hand side of the machine, 

the workpieces are supplied on a strip accumulator. With 

the integrated loading concept WFL has reduced the space 

requirement by 50 % in comparison to a conventional production 

cell. The M20’s integrated loading feature is designed 

for chuck parts with a Ø of up to 300 mm and a workpiece 

weight of 15 kg. For shaft parts a workpiece Ø 100 mm and 

a workpiece length of 300 mm is possible. 

The turning-boring-milling unit with integrated spindle 

motor and a B-axis with torque motor are entirely new features. 

The individual tool holder with B-axis on the lower 

slide is another highlight. The upper and lower system can 

be used simultaneously and both systems are supplied by a 

reliable and dynamic tool changer from a shared magazine. 

This allows even complex components to be machined with 

optimal efficiency, and the setup of the tool turret is no longer 

necessary. The tool can be moved up to 100 mm below the 

turning center, so drill patterns with Ø of up to 200 mm can 

be produced on the face with a high level of precision and 

without turning the C-axis. 

Five-axis machining is planned precisely, right down 

to the last detail, to ensure smooth production of 

turbine blades on a MILLTURN from WFL 

Universal machining solutions 

with the M50-G MILLTURN 

The new M50-G MILLTURN generation, with greater center 

distance and improved performance, was another highlight 

of AMB. The optional center distance of 6000 mm enables 

efficient machining of long shaft parts. When designing the 

M50, WFL implemented some of the features of the larger 

M80. The machine’s existing potential is fully utilised, particularly 

in terms of the increased drive power, combined with 

the HSK-A100 or Capto C8 tool accommodation. The turning 

Ø is available up to 670 mm and the fully developed, proven 

machine concept of the M50 MILLTURN has received an 

attractive ergonomic finish. A separate pick-up magazine 

for very long and/or heavy tools is available. Workpieces 

with a length of 1600 mm can be automatically inserted and 

changed. The standard disc magazine can be expanded to up 

to 200 positions. 

On this machine a turbine blade/screw was machined live. 

Components such as turbine blades or plasticising screws require 

both dynamic and stable machining concepts. A special 

clamp from the manufacturer Grasch was used to clamp 

rectangular raw materials easily and securely, a fundamental 

requirement when machining turbine blades. Technologies 

known as ‘helical spiral milling’ and ‘helical longitudinal 

milling’ are used to machine the blade. 

Smart tools: ICOtronic and ultrasound measuring 

The sensors of the ICOtronic tool provide information on the 

machining process as close as possible to the cutting edge. 

This optimises milling processes and also increases the machines’ 

productivity, as shown at AMB. 

Integrated production cell for automatic loading 

and unloading: intCELL 

Ultrasound measuring was also demonstrated live at the 

trade fair. The automatically loading ultrasound measuring 

probe enables a fully automated measuring process. The large 

measuring range (1.5 - 30 mm) offers further benefits. Ultrasound 

measuring is extremely well suited for calculating the 

hole run-out and Ø of very deep holes. 

further information: www.wfl.at 



360° solutions for successful future manufacturing 

HELLER’s trade fair appearance at AMB focused 

on 360° performance – a holistic view of the requirements 

of modern manufacturing. Based on this principle 

the machine tool manufacturer wants to provide 

customers with successful solutions helping them 

to produce reliably and at competitive per-piece costs 

in day-to-day manufacturing – with maximum availability 

and productivity – even in challenging times. 

Full spectrum of productivity – 

HELLER machines at AMB 

With the H 4000 and HF 5500, HELLER showcased the latest 

generation of highly productive 4-axis and 5-axis machining 

centers at AMB. 2020 the company already launched the 

second generation of the horizontal 5-axis machining centers 

from the HF series. The goal of this further development was 

to enable an even more universal application, both in single-part 

and series production. In addition to the existing 

options of interpolation turning and the use of the HELLER 

out-facing head system, the company now also offers a swivelling 

NC rotary table with turning function especially for 

the HF 5500 exhibited at AMB to cater to the various requirements 

in terms of complete machining. The prerequisites for 

this turning function are enforced drives in Z and A. The 

enforced Z-axis is equipped with two ball screws and two 

direct driven absolute measuring systems combined to a 

gantry-drive system. Moreover, the HF 5500 is equipped with 

a DDT (Direct Drive Turning) rotary table, a spindle with 

locking function for secure fixing of turning tools, the balancing 

technology cycle and with Siemens NC turning cycles. 

The 4-axis machining center model H 4000 is the fourth 

generation of the H series to be launched in the market. The 

machining center is equipped with the SPEED equipment 

package for minimal idle times and highest dynamics, the 

SC 63i Speed Cutting Spindle (16,000 rpm, 40 kW, 103 Nm) 

and a chain-type tool magazine with 80 storage places. In 

Rotary pallet storage 

particular, manufacturers and suppliers from the broad 

industrial sector (including machine builders, contract 

manu facturers, energy and fluid technology companies) are 

using the horizontal 4-axis machines for the production of 

medium to large volumes. 

Automation solutions from HELLER – 

flexible, value-adding, competitive 

The main purpose of automated manufacturing and production 

centers is the reduction of idle times in order to optimise 

system availability. For this purpose HELLER offers proprietary 

automation solutions that can be optimally combined 

with the highly productive HELLER machining centers. Due 

to the wide variety of market requirements this portfolio is 

complemented by a range of specialised solutions HELLER is 

able to offer, based on best-in-class partnerships. 

The aforementioned H 4000 is equipped with a flexible 

robot automation from HELLER. The robot cell, equipped 

with a Gressel gripper system, is used for workpiece loading 

to the machining center and enables flexible workpiece 

handling. A workpiece storage system to ensure unmanned 

shifts was shown along with a demonstration of the user 

interface for easy and intuitive operation of the solution. 

HELLER also presented the RSP 12H2 rotary pallet storage. 

With a total of eleven pallet storage locations the automation 

solution enables flexible and automated handling of machine 

pallets and is predestined for series production of small and 

medium batch sizes. 

Equipped for the factory of the future – digitisation 

In the context of Industry 4.0 and digitisation in production, 

HELLER developed years ago an innovative concept that 

further increased the productivity of HELLER machining 

centers, for example through extended functionalities and 

service options. 

HELLER out-facing head 

further information: www.heller.biz 


39


Seen at IMTS 

ANCA launches its premium, 

next generation machine range 

The new MX7 ULTRA can manufacture large volumes of endmills 

and other cutting tools of the highest accuracy and quality. 

The minute size of a micron is beyond the human eye, but in becoming 

even more precise and moving from micrometers to nanometers, 

ANCA offers the highest accuracy and quality in a cutting 

tool in the market. New software, hardware and design features are 

combined to make significant advances in surface finish, accuracy 

and controlled runout, to deliver batch consistency from the first 

ground tool to the thousandth. 

Highest quality and performace cutting tools with MX7 ULTRA 

Pat Boland, ANCA co-founder says: “The MX7 ULTRA is a significant development 

in precision machine design and will change the industry expectations 

for accuracy and tool life. Achieving these outstanding results has only 

been possible because of our extensive experience working with customers to 

manufacture the highest quality cutting tools over many years. At ANCA we 

are always designing and innovating to find better customer solutions and I 

am very proud of the ANCA team that has developed the MX7 ULTRA.” 

Automation on MX7 ULTRA with 

ANCA’s Robomate 

“The ULTRA machine is truly market changing. It is the culmination of 

ANCA’s elite technology, deep industry knowledge and customer experience 

in grinding,” says Thomson Mathew, ANCA product manager for the MX 

series and software products. 

Unlike its competitors ANCA is vertically integrated. This provides a significant 

advantage as it means ANCA teams can develop and manufacture 

their own machines from base to canopy – including controls and drive 

systems, design and simulation software and even machine monitoring software. 

Owning all the technology means engineers and designers can consider 

the entire machine as a single system when developing new solutions. 

“We wanted to create technology that could produce premium cutting tools 

that are above the current market standard in both accuracy and tool life. We 

introduced nanometer resolution into our axis, which is new to the cutting 

tool market. The result is a perfect example of ANCA’s vertical integration 

capabilities as we have the in-house ability to fine tune or develop the new 

algorithms for our drives to make this happen.” 

Quality from every angle with MX7 ULTRA 



“Cutting tools like ballnose, corner radius, barrel shape 

ballnose and double corner radius endmills are used widely 

across industries including diemold, aerospace and power 

generation. The surface finish quality, accuracy and runout 

are critical for the performance and cutting life in all applications 

– so our customers want a guarantee that their first tool 

will be exactly the same as the hundredth, or thousandth. 

The MX7 ULTRA can produce high quality cutting tools to 

suit all customer needs to satisfy all industry types.” 

The MX7 ULTRA superior performance highlights 

➢ greater control for the velocity and acceleration or 

deceleration along with machine jerk limits: 

To increase the stiffness of the C-axis, the MX7 ULTRA 

combines developments to the nanometer or micro 

degree resolution in the linear and rotary axis, 

tuning parameters, several system enhancements 

and major mechanical changes. 

➢ ULTRA-fast response to internal or 

external disturbances: 

ANCA’s newly designed servo control algorithm allows 

silky smooth motion of an axis with the use of a unique 

algorithm and nanometer measurement in the control 

system. This will create finer cutting edges and 

eliminating micro-chips making it more efficient 

while used in actual machining of materials. 

➢ better cycle time and higher productivity 

of high-quality cutting tools: 

The unique algorithm is key to the performance of the 

machine and ensures outstanding tracking performance. 

It also allows ULTRA-performance of the servo system 

without using a complex, complicated or expensive 

mechanical system. 

➢ reduces setup times and scrap: 

Cutting-edge software has been developed by ANCA to 

ensure batch consistency in large volumes. LaserUltra 

is part of the MX7 ULTRA package to maintain 

consistency and accuracy of the grinding process which 

includes in-process measurement and compensation to 

accommodate wheel wear and other external variations 

during large batch grinding. Its analog capability can 

maintain less than +/- 0.002 mm line form accuracy of any 

profile which includes ballnose and corner radius tools. 

The MX7 ULTRA includes: 

▶ nanometer control system 

▶ new servo control algorithm for smooth motion 

▶ system and mechanical upgrades enhance 

stiffness and rigidity 

▶ in-process measuring, balancing and runout 

compensation for consistent accuracy 

▶ Motor Temperature Control (MTC) – compensation 

for thermal expansion on the grinding spindle, 

and specialist training support in how to grind 

industry leading cutting tools 

Tool runout compensation on MX7 ULTRA 

➢ increased wheel life and better-quality tools: 

Tool and wheel performance can be further optimized by 

the iBalance software, which guides a user to the optimal 

grinding position and RPM for vibration monitoring and 

balancing the wheelpack inside the machine. Correctly 

balanced wheelpacks result in superior surface finish and 

reduced wheel wear due to the elimination of wheel 

vibration. 

➢ consistency in finished tool quality: 

A major inclusion in the MX7 ULTRA package is the 

total tool runout measurement and compensation 

operation in iGrind. When an endmill is in rotation it is 

important that each tooth hits at the exact same spot along 

the workpiece for longer tool life and efficient cutting. 

Every tool in the batch can be measured and compensated 

for runout to make sure the entire batch is within a 

tolerance of 0.002 mm. It is another piece of assurance 

that the first endmill will be as good as the last. 

➢ consistent spindle thermal stability: 

Motor Temperature Control (MTC) is a patented 

(US PAT. 11,394,331) innovation built into the motor 

spindle drive firmware. Smart control algorithm actively 

manages and maintains the temperature of motorized 

spindles in the MX7 ULTRA. Dramatically reduced 

machine warmup time means production can start sooner, 

once the machine has reached thermal stability. This 

improves productivity and machine use. Consistent 

thermal stability of the spindle over time regardless of 

changes in load or speed, or coolant temperature, greatly 

improves the dimensional stability of grinding results. 

➢ post grinding processes: 

The smoother, finer cutting edge and surface finish as 

a result of the combination of all the above including 

the nanometer control will assist in all post grinding 

applications like edge preparation and coating. A finer 

edge that has been properly prepared has greater stability, 

which reduces the likelihood of it chipping, while also 

decreasing surface roughness which can cause increased 

friction between the tool and the workpiece. 

further information: www.anca.com 


41


The answer to new requirements? 

New solutions 

This year’s AMB in Stuttgart was all about ‘Smart 

Manufacturing Solutions’ for SW. Trade fair visitors 

could expect an exciting insight into the company’s 

product highlights, including a world premiere with 

which the global player goes beyond the standards of 

the manufacturing industry. 

“We see ourselves not only as a ‘machine provider’, but 

rather as a ‘solution provider’ that offers its customers intelligent, 

digitally networked, energy-efficient and future-proof 

manufacturing solutions. In other words, we provide ‘Smart 

Manufacturing Solutions’ consisting of our proven standard 

machine portfolio, modular automation modules and digital 

services,” explains marketing manager André Harter. Setting 

new benchmarks and actively shaping the future of the industry 

is the vision. Rapidly changing requirements in new 

industries such as e-mobility are opening up new potential 

for manufacturing solutions, which SW knows how to address. 

A SW expert provided information on these and many 

other topics in live talks in front of a six-meter LED wall at 

the trade show booth. 

World premiere: 

produce larger parts with the same footprint 

A special highlight at AMB 2022 was the world premiere 

of the new BA 711 space, a flexible single-table machine for 

small and medium series production of precision parts made 

of cast iron, cast steel or steel. 

“The machine’s footprint is almost identical to previous 

models. But the new design eliminates the partition wall 

in the machine interior, so the space available in the machine 

has been expanded enormously,” explains Harter. The 

BA 711 space has effectively not become any larger, but now 

it can machine considerably larger parts such as engine 

blocks, chassis parts or transmission housings for agricultural 

and construction machinery, trucks, rail vehicles and 

much more. 

Looking to the future: 

why multi-spindle machines and 

automation modules are the right choice 

lndustries such as e-mobility in particular place great demands 

on manufacturers in terms of flexibility and future 

viability. SW has been successfully supporting its customers 

in these areas for years and has always focused on 

The new SW single-table machine BA 711 space for 

small and medium batch production 

multi-spindle machining centers. This year at AMB, for 

example, the benefits of energy-efficient multi-spindle machines 

were once again presented. “A four-spindle machine 

shortens cycle times by up to 60 % compared to singlespindle 

machines. At the same time it saves around 70 % of 

the floor space and consumes only about half the amount 

of energy,” says André Harter, citing important factors for 

a future-proof and sustainable investment. The latter in 

particular is ensured by the fact that SW also supports its 

customers with customized automation solutions that can be 

flexibly retrofitted. “We focus on reducing non-productive 

time, increasing quality, and improving ergonomics. With 

a modular system divided into hardware and software, we 

always find the optimum solution.” 

Market innovation: 

one interface for everything – made by SW 

SW is increasingly distinguishing itself as a solution provider 

and holistic system partner. An important key component 

is digitally networked communication for optimum interaction 

between the machines, systems and optionally available 

add-on modules. For example in order to be able to integrate 

energy-carrying tools into the machine tool easily and independently 

of the manufacturer, SW presented an in-house 

development at AMB: the HSKi spindle. “Our services range 

from intelligent interfaces for connecting external add-on 

modules with the help of our HSKi spindle to software programs 

and cloud solutions that enable greater transparency 

and data availability during manufacturing processes – that’s 

what we call ‘life data’ at our company,“ says Harter, summarizing 

the wide range of process optimization options. 

further information: www.sw-machines.com 



The perfect machine for the entry-level segment 

STUDER S100 universal internal cylindrical grinding machine 

High-precision, flexible and reliable: with the new S100, 

STUDER presents the ideal universal internal cylindrical grinding 

machine for the entry-level segment. Its excellent price-performance 

ratio makes it the perfect machine for a wide range of internal 

grinding applications. 

“The S100 internal grinding entry-level machine perfectly complements 

our comprehensive internal grinding portfolio”, explained CSO Sandro 

Bottazzo, when presenting the S100 at BI-MU Exhibition for Machine Tools 

in Milan. 

Like all STUDER cylindrical grinding machines, the S100 has also a 

machine bed made of Granitan®. Its outstanding dampening, and thermal 

characteristics ensure consistently good 

grind ing results and the renowned STUDER 

precision. During the development special 

attention was given to a simple and efficient 

design of the components, making operation 

and maintenance easier for the operator. 

However, the equipment of the S100 also 

makes it suitable for grinding a universal 

spectrum of parts comprising of geometrically 

defined basic forms and contours, which 

can be generated with interpolating axes. 

Flexible equipment ensures a 

diversity of parts 

The machine can be equipped with up to two 

internal grinding spindles or one internal and 

one external spindle. In addition to a fixed 

wheelhead, it can be equipped with a manual 

with a 2.5 degree Hirth and, in its optimum 

configuration, with an automatic wheelhead 

with 1 degree Hirth. A synchronous motor 

drives the grease-lubricated internal and external 

belt spindles. The machine is operated 

by the Fanuc 0i-TF PLUS controller, together 

with the proven STUDER operating system. 

A further advantage of the S100 is the automation 

option. On request it can be equipped 

with a loading interface and an automatic 

sliding door, enabling automatic operation 

and the production of large series. 

Typical workpieces for production on the 

S100 include collets for toolmaking, bearing 

rings, ball bearings and cylinders, as well as 

hydraulic control valves in small series. 

External and internal machining of flange 

parts or grinding of threads or non-circular 

forms is also possible. The competent and reliable 

STUDER Customer Care is naturally 

also on hand to provide advice and technical 

support for the S100. 

STUDER S100 wheelhead 1× internal grinder 1× external grinder 

further information: www.studer.com 


43

components 

AMB premiere for the smart chuck jaw 

From now on, clamping is smart: Röhm, the 

clamping and gripping specialist based in Sontheim 

an der Brenz (Baden-Württemberg, Germany), 

presented its world premiere iJaw at AMB in Stuttgart. 

It is the first chuck jaw ever to be equipped with sensor 

technology and wireless data transmission. It allows 

the clamping force to be measured in real-time directly 

during machining. Data is transmitted to a gateway 

via the industry standard IO-Link Wireless. 

Great news: OEMs (the original equipment manufacturers) 

can now integrate a smart chuck jaw into their machines and 

PLC controllers displaying clamping forces on their HMI (human 

machine interface) displays. iJaw development partner 

DMG Mori is so enthusiastic about the functionalities that 

its machine tools can now be configured with iJaw. Other 

partners, such as WFL Millturn, Mazak and Emco also presented 

machines with iJaw applications at AMB in Stuttgart. 

But existing inventory can also be updated to smarter 

clamping with a retrofit “On-Premises” interface and display 

independent of the machine’s electronics. This after market 

iJaw upgrade is also available for most non-Röhm quick 

change jaw chucks. 

Available geometries of the iJaw 

Revolution in metalworking 

“With iJaw we are effectively revolutionizing the manufacturing 

process in metalworking. This is because real-time measurement 

of the clamping force during the machining process 

provides the user with a whole range of benefits. This starts 

with higher machine availability because setup times can be 

reduced and machining processes accelerated. This reduces 

part costs on the one hand, while part quality increases on 

the other. This is pure process optimization and a real milestone 

in the digitalization of manufacturing. Overall, sensorcontrolled 

workpiece machining is, of course, much safer 

than conventional manual clamping by feel,” says Gerhard 

Glanz, CEO of Röhm GmbH. 

Safety even with thin-walled workpieces 

Gone are the days when the clamping force was set higher 

than necessary in order to play it safe. “Especially with 

thin-walled components or sensitive surfaces, this is known 

to be counterproductive because too much clamping force 

here quickly leads to deformation or even crushing of the 

workpiece. You can significantly reduce rejects with precise 

sensor-controlled machining,” says Glanz. 

Structure of the sensorized clamping jaw iJaw from Röhm 

This is how the iJaw works: The forces applied by the jaw 

are detected by an integrated sensor and the data is transmitted 

and processed accordingly. The iJaw measures not only 

the actually applied forces of the internal and external clamping 

but also its own temperature. The charging status of the 

battery is also always visible. If data from the pressure display 

is available, the iJaw can also be used to monitor the condition 

and efficiency of the power chuck. The iJaw measures in 

real-time during machining. For this purpose, it has a suitably 

robust hardened steel and waterproof (IP 68) design. The 

transmitting antenna has a cover made of high-temperature 

resistant plastic to protect against glowing chips. 


components 

Retrofitting made easy 

It will soon be possible to very easily 

retrofit machine tools iJaw. In addition 

to installing the chuck jaws with 

integrated sensors, users only need 

the gateway with an adjacent industrial 

processor and a display for 

accessing the data. This can be an 

instaled PC or a mobile tablet. The 

system is then controlled by the iJaw 

Mobile web app that establishes the 

connection between the iJaw and 

the gateway. “Through iJaw Mobile 

users can then create jobs, manage 

their jaws, and, of course, receive 

alerts, for example if the minimum 

clamping force is not reached,” 

explains Glanz. 

With the “iJaw Mobile” app, the iJaw is controlled and 

clamping force data is visible in real time 

Gateway as a data hub 

The iJaw transmits the measured data wirelessly to a gateway via the robust IO-Link 

Wireless protocol with a high sampling rate of 100 Hz. 

The gateway consists of an industrial PC for data processing and interfaces and 

the IO-Link Wireless Master. The gateway communicates with the iJaw via IO-Link 

Wireless technology. The data is transferred either via ethernet to a processor via the 

integrated LAN interface and then accessible via WiFi for On-Premises displays. Of 

course, the data can also be processed directly in the machine tool’s PLC. For this 

purpose, the gateway is connected to the machine via the integrated Profinet interface. 

The machine controller can process the data in real-time and display it on the 

machine panel. The universal iJaw gateway from Röhm uses only standard protocols 

and interfaces. Their specification is freely accessible. Further sensors – your own or 

also from third-party suppliers – can be integrated with the universal gateway without 

additional hardware. 

Clamping force curve of a component in the series process – 

the deviation at the end indicates irregularities 

Soon available in the cloud: 

the digital fingerprint 

of machining 

The option of utilizing cloud services 

with the iJaw system will also soon be 

available. This will enable additional 

functions such as process or productivity 

analyses and the docu mentation 

of large quantities of measurement 

data. With the iJaw Mobile app 

users can thus access the data from 

anywhere and evaluate processing 

parameters or have warning messages 

displayed. “Especially in the 

production of components with 

mandatory documentation, such 

as aerospace manufacturing, this is 

a very attractive feature. The iJaw 

archives the digital fingerprint of the 

machining process, so to speak,” says 

Glanz. 

Flexible in use 

The iJaw can be mounted and used 

on all lathe chucks with a suitable 

(standard) jaw interface like any 

other chuck jaw. For the market 

launch, the iJaw is available as a 

single-stage jaw, two-stage jaw, and 

block jaw for lathe chucks with 

straight gearing in the sizes 260, 315, 

and 400 as well as a special jaw for 

independent chucks. One such chuck 

from Röhm is the Duro-A RC power 

chuck with the quick jaw change 

feature. Various interchangeable 

hard and soft clamping inserts are 

locked onto the jaws with screws to 

adapt the jaws to different workpiece 

geometries. 

further information: www.roehm.biz 


45

components 

A whole new range of products dedicated to rotary 

Rollix, department of the Defontaine Group, 

announced the launch of its new range: Rollix RT. 

Highly focused on innovation, Rollix’s R&D teams 

have developed the Rollix RT product range to satisfy 

all industrial companies with rotary tables, indexing 

tables, machine tool tables, machining centers, milling 

and drilling machines. Rollix offers this range of dedicated 

rings from 200 to 1,030 mm. 

“Rollix has been the European leader in slewing rings and 

bearings for more than 40 years,” explains Nicolas Charron, 

sales director for the Rollix brand within the Defontaine 

Group. He adds: “With Rollix RT we are expanding our range 

of precision bearings. After the Compact CB, Compact HP 

& P, Compact XL and Compact Light ranges, the RT range 

offers slewing rings to specifically meet the machining precision 

and performance needs of machine tools. We target 

both new machine providers and the aftermarket. Finally, our 

stock strategy allows us to make immediate deliveries.” 

The main strengths of the range are: 

→ interchangeability with the standard references on the 

market: similar speed range, identical precision 

→ longer life than the market average, if used and maintained 

correctly 

→ 5 year parts warranty on 

new machine tools 

Technical characteristics 

of the Rollix RT range: 

→ very high rigidity 

→ high rotational accuracy 

→ high geometrical quality 

→ high tilting moment capacity 

→ range from 200 to 1,030 mm; 

→ sable from - 25° C to + 120° C. 

Made of 100c6 steel, each 

product in the Rollix RT range 

is composed of three rows of rollers. 

Rollix is committed to maintaining its 

customers’ productivity 

Rollix RT slewing rings are ideal for applications requiring 

high positioning accuracy. Rollix teams are committed to 

short lead times and availability of its range in France and 

on the five continents thanks to its distributors network for 

reduced supply times. In addition to these commitments, 

Rollix offers optimal customer service to maintain the productivity 

of its customers’ production lines. The Rollix 

RT range is available on the Rollix e-shop for instant order 

processing whatever the time zone. 

further information: www.defontaine.com 

Three jaws for perfection 

The success story of the TANDEM3 modular 

system continues – the new 3-jaw clamping force block 

offers even greater design freedom for automated 

machine loading in four actuation variants. 

All TANDEM3 power clamping blocks are distinguished by 

their high clamping force and accuracy, together with a compact 

design. This makes them the ideal companion for process-reliable 

workpiece clamping in confined spaces. Various 

pneumatic monitoring functions, optional clamping force 

amplification for pneumatic actuation and an extensive range 

of accessories make them perfectly suitable for automated 

use in the metal cutting industry. This makes the TANDEM3 

clamping force block the ideal companion for small and extremely 

large batch sizes in all industries. 

Four variants for cylindrical clamping 

The new 3-jaw clamping force block constitutes a further 

module for stationary clamping of cylindrical workpieces 

for the TANDEM3 series. Even force distribution ensures secure 

and repeatable clamping. Like its 2-jaw counterpart, it 

also comes with a sophisticated lubrication system that ensures 

high efficiency and constant clamping forces. The optimized 

external contour ensures controlled diversion of chips 

and means the workpiece is easily accessible in any machining 

operation. Additional cover 

plugs prevent the clogging of 

chip clusters. The clamping device 

is available in pneumatic 

(KRP3), hydraulic (KRH3), 

spring-loaded (KRF3) versions 

and will soon be available 

in an electric version, too (KRE3). Integrated monitoring 

functions make the centric clamping also useable in automated 

machine loading. They enable the basic jaw position 

to be monitored via dynamic pressure or the workpiece 

locating surface checked reliably during automated 

loading for instance. By means of standardised console 

plates, vises can be mounted on the machine table or the 

VERO-S quick-change pallet system quickly and easily or 

flexibly interchanged. 

The 3-jaw vise is available as a standard or long-stroke version 

in four sizes from 100 to 250. Its clamping force ranges 

from 18 to 66.5 kN. With its extensive modular system and 

versatile range of accessories comprising chuck jaw, fixing 

and monitoring options, SCHUNK offers clamping solutions 

for every application. 

further information: www.schunk.com 


Filtration solutions that increase efficiency 

and sustainability 

components 

The Filtration Division of the energy 

management company Eaton exhibited 

at Word Filtration Congress. This 

event is the premier global forum for 

scientists, engineers and practitioners in 

filtration and separation, it took place 

October 5 th -9 th in San Diego, CA. Eaton’s 

filtration specialists showcased numerous 

solutions for industrial, life sciences 

and hydraulic filtration applications. A 

special focus was placed on highly efficient 

water filtration solutions. 

One of the water filtration highlights will be 

Eaton’s model 2596 automatic backwashing 

self-cleaning strainer, a motorized unit 

designed to continuously remove entrained 

solids from liquids and pipeline systems, prevent 

damage to expensive pipeline system 

components, lower energy consumption, and 

minimize maintenance costs. 

For applications where shutting down processes 

is not an option, Eaton’s model 53BTX 

duplex strainer provides years of trouble-free 

service, protecting expensive pipeline system 

components from damage by unwanted particles. 

Eaton’s low maintenance DCF series was 

also on display. These are considered the most 

efficient mechanically cleaned filters on the 

market, operating at a consistently low differential 

pressure. They deliver simple, reliable 

operation in which a low initial investment is 

a key driving factor. 

Visitors had the opportunity to learn about 

the high-performing bag filters. Eaton’s 

TOPLINE TM single bag filter housing features 

a side inlet, flow through top for easy filter 

bag change-outs and provides optimum sealing 

of the filter bag. When used with the 

Eaton filter bags, such as DURAGAF TM , 

HAYFLOW TM or MAX-LOAD TM filter bags, the 

filter area can be increased by up to ten times 

compared to a standard filter bag while minimizing 

environmental footprint. 

In addition to the water filtration technologies, 

Eaton also showcased filtration solutions 

for life sciences. This includes the upgraded 

BECODISC® BC activated carbon stacked disc 

With flow rates up to 35,000 gpm, model 2596 automatic self-cleaning 

pipeline strainers are ideal for applications that demand continuous flow, 

simplified maintenance and worry-free operation in industrial, sewage, 

water treatment and pulp and paper processes 

cartridges with BECO CARBON TM depth filter sheets that offer particularly 

high adsorption properties for the demanding filtration of liquids. In the 

realm of hydraulic filtration solutions, Eaton showed various filter elements 

for trouble-free operation when filtering abrasive or water-based fluids and 

cooling lubricants to help protect critical system components and achieve 

cleanliness class requirements. 

About Eaton’s Filtration Division: 

Eaton’s Filtration Division is a leader in liquid filtration that can help companies 

improve product quality, increase manufacturing efficiency, protect 

employees and equipment and help achieve sustainability goals. Worldwide 

Eaton employees make a difference for their customers by creating an exceptional 

customer experience, solving problems with application expertise 

and developing innovative filtration solutions. Eaton’s filtration products are 

manufactured and sold worldwide. 

further information: www.eaton.com 


47


Showroom for the automation of tomorrow 

The Liebherr Tech Center 

The Kempten Tech-Center of Liebherr Automation Systems provides 

a space for trials on high-quality automation solutions. The 

current focus is on vision-based robotics, bin picking and processes 

in battery pack assembly for e-mobility. The Tech Center is a pillar 

of Liebherr’s expertise and innovation potential in the field of automation. 

Customers benefit from the opportunity to carry out tests 

using their own workpieces on the equipment at the center. 

Complete bin picking solutions 

As one of the leading solution providers in 

the field of random bin picking, Liebherr tests 

the interaction of the individual components 

required for the automated removal of workpieces 

and feeding into the manufacturing 

line by robots at the Tech Center: software, 

vision systems, gripping technology and 

robotics. Where many other suppliers cover 

individual areas such as camera technology, 

Liebherr offers complete solutions. “We deal 

with all application areas and can therefore 

select the optimum system for our customers,” 

explains Thomas Mattern, development 

manager for automation systems. “Our portfolio 

includes everything from technology 

packages for integrators to complete robot 

cells as plug-and-play solutions.” 

But it’s not just the company’s own tests that 

are running at the bin picking station. Trials 

and feasibility studies for customers are also 

carried out here – from part recognition to 

removal with complete box emptying to 

position-dependent positioning in the manufacturing 

line (see info box). “Every workpiece 

has different challenges: crank shafts 

get caught, sheets stick to each other, anticorrosion 

film casts shadows or covers parts,” 

Mattern explains. “We can test all these 

scenarios really effectively here.” 

Position-accurate joining of high-voltage plug connections 

with two cooperating robots 

There is a concentrated atmosphere in the Tech Center. A test setup for 

developing gripper strategies for a customer is documented at the bin picking 

station. Next door the test facility is running various core processes 

of battery pack assembly for e-mobility is being tested on the facility. Opposite 

an innovative solution for plugging battery module connections is being 

tested. 

Space for exchange and customer trials 

The 700 m 2 hall quite literally offers a great deal of space for development 

and innovation. There is even room for large-scale systems. Until recently, 

the PHS Allround 3000 had been tested here, a variant of Liebherr’s 

modular pallet handling system for weights of up to three tons. There is also 

scope for discussion and sharing ideas with customers and within the team. 

The test hall, customer area and meeting rooms are all under one roof allowing 

visitors to experience first hand the automation of tomorrow. Customers 

also have the opportunity to commission or carry out trials with their own 

workpieces. 

E-mobility: core processes of 

battery pack assembly 

In the field of e-mobility Liebherr is working 

on the end-to-end automation of battery 

pack assembly. The focus here is on the 

Bin picking – customer trials: 

1. scan: testing and selection of a suitable 

vision system with customer workpiece 

2. simulated removal: simulation of a 

workpiece-specific gripping process 

and checking how much the bin 

has been emptied 

3. real test removal: components are 

gripped in reality by a robot and a 

workpiece-specific gripper 

4. real test with loading: removal and 

gripping position-dependent deposit 

placement of the workpieces 



Automated assembly of high-voltage battery systems for e-mobility 

process reliability of the joining, screwing and dosing assembly processes 

as well as on the material flow and material supply to the assembly equipment. 

Liebherr tests the automation of these processes in advance as a simulation 

on a “digital twin” and then demonstrates the process capability on a 

facility test equipment. 

Here tests are run on the detection, positional dependency and modular 

assembly, module connectors and the cover of the battery housing in order 

to screw them in place with positional accuracy. Another focus is on the dispensing 

of one- and two-component adhesives and sealants as well as heatconducting 

pastes, including process monitoring during dispensing bead 

detection using 3D vision systems. “This, in combination with robotics, is 

a highly demanding process in e-mobility,” explains development engineer 

Jan Pollmann. “We are working on process reliability to pave the way for 

customers to automate.” Customers can also 

use this system by request for tests on their 

own battery packs, therefore benefiting from 

the high-tech infrastructure in Kempten. 

Innovative: automation of 

flexible plug connections 

A unique, innovative technology is being 

tested at the system over the road – the automated 

assembly of flexible high-voltage cables 

with plug connections for battery modules. 

Two synchronously operating robots with a 

patented combination gripper join the plug 

connections in a precise position with the 

aid of cameras. Interest in these connectors 

is growing in the industry because, unlike 

conventional rigid module connectors, they 

are easier to assemble, safer due to their electrical 

insulation and more robust in use. This 

results in additional application possibilities 

for the automation of plug-in cables in battery 

packs, which are developed and tested individually 

for each customer. 

Win-win situation 

The Tech Center represents Liebherr’s innovation 

potential in automation. Customers 

benefit from the extensive expertise of 

experts, who respond to individual requests, 

test products and processes in the test facilities. 

“Liebherr has therefore created a winwin 

situation for both sides,” says Thomas 

Mattern, summarizing the benefits. 

Robot cells for bin picking 

further information: www.liebherr.com 


49


Well positioned at the SPS 

When SPS trade fair starts November 

8 - 10 in Nuremberg, also Aerotech, as 

a specialist for motion control and positioning 

solutions, will be there. The new 

release 2.3 of the motion control platform 

Automation1 and several linear motor 

stages of the PRO-Series will be on 

display – controlled on the booth with 

Automation1. 

Automation1 – 

user-friendly motion control 

Visitors to the Aerotech booth can see how 

positioning systems and peripheral components 

can be controlled in a user-friendly way 

using just one control platform. The Automation1 

suite replaces previous control platforms 

(A3200, Ensemble and Soloist) with 

new and more powerful features in an easyto-learn 

and intuitive architecture. “Our 

latest release 2.3 comes with several new 

features such as the “Machine Apps HMI development 

tool”. With this fully customisable 

tool we have replaced the previous CNC 

user interface and in this way revolutionized 

user interfaces for drive systems,” says 

Simon Smith, European director of Aerotech, 

who knows this from various tests and live 

installations. 

In addition version 2.3 of Automation1 has 

successfully left the beta phase and is now 

officially EtherCAT-compatible, which enables 

connection to PLC-based systems and 

thus expands the options for high-precision 

motion processes when embedded in a conventional 

system with lower precision. Currently 

still in beta, but already part of the 

new version are the touchscreen functions 

for MachineApps support and the Python 

API configuration interface. 

Automation1 also has improved data visualisation 

and programming module usability. 

Command Queue (Q-mode in A3200) and 

Position/Speed/Torque control via analog 

input have also been added and optimised. 

“With Automation1 2.3 we provide the users 

of our positioning systems with complete 

machine control for all components and thus 

go significantly further than conventional 

motion controls,” asserts the Aerotech 

European director. 

SPS 2022: Aerotech will present its Pro-Series industrial stage series 

with direct-drive linear motor 

User-friendly control platform: “Automation1” combines usability 

and high-tech features in a motion control platform 

Linear motor stages in action 

Several PRO-LM linear stages controlled by Automation1 are on display at 

the Aerotech booth. The PRO-Series stages are available either with direct 

drive by a linear motor or with a ball screw. “Based on the set-up, we can 

demonstrate our extensive know-how in the design of these linear stages, 

including cable management,” explains Simon Smith. “They are able to travel 

at high speeds with excellent speed control. It is true that not only the speed 

and positioning performance is a characteristic, but also the robustness.” 

The sealed mechanical bearings also make the PRO-LM linear stages 

insensitive to any kind of contamination; they are equipped with a lowfriction 

sealing system that substantially reduces the maintenance effort 

in industrial use. 

further information: www.aerotech.com 


impressum 

ISSN 2628-5444 

publisher 

Benno Keller 

phone + 49 (0)911 - 2018 200 

fax + 49 (0)911 - 2018 100 

keller@harnisch.com 


Eric Schäfer 

phone +49 (0)911 - 504 98 82 

fax +49 (0)911 - 506 38 32 

eric.schaefer@harnisch.com 

managing editor 

Christiane Ebner 

phone +49 (0)911 - 2018 260 

fax +49 (0)911 - 2018 100 

ebner@harnisch.com 

publishing company 

Dr. Harnisch Publications 

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Dr. Claus-Jörg Harnisch 

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Eschenstrasse 25 

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advertising Germany, Austria, Switzerland 

Thomas Mlynarik 

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Four issues per year 

printed by 

Schleunungdruck GmbH 

Eltertstrasse 27 

97828 Marktheidenfeld, Germany 

VAT DE 133 510 873 

editorial 

Aerotech, Inc. .......................50 

ANCA Pty Ltd. ..................... 40 

CERATIZIT 

Deutschland GmbH ......... 14, 15, 25 

Defontaine France .................. 46 

EATON Corporation .................47 

EMAG Group .......................36 

FILTECH fair .......................22 

Fraunhofer Institute for 

Manufacturing Engineerig 

and Automation IPA ................32 

Fritz Studer AG .....................43 

Gebr. Heller Maschinenfabrik GmbH ..39 

Gühring KG ........................21 

Hartmetall-Werkzeugfabrik 

Paul Horn GmbH ...............16, 17 

Hoffmann Group .....................9 

IMTS fair .......................... 24 

company finder 

KYOCERA Fineceramics Ltd. .........12 

Lach Diamant Jakob Lach 

GmbH & Co. KG ............... 18, 26 

Liebherr-Verzahntechnik GmbH ..... 48 

LMT Tools GmbH & Co. KG ..........11 

MAPAL Fabrik für Präzisionswerkzeuge 

Dr. Kress KG. . . ............... 20, 23 

Mikron AG, Division Tool .............6 

MMC Hartmetall GmbH .............10 

Platinum Tooling Technologies, Inc. ...31 

Röhm GmbH Sontheim ............. 44 

SCHUNK GmbH & Co. KG .......... 46 

Schwäbische 

Werkzeugmaschinen GmbH ........ 42 

VOLLMER WERKE 

Maschinenfabrik GmbH ............35 

WFL Millturn Technologies 

GmbH & Co. KG ...................38 

The articles contained in this magazine, 

including the illustrations, are subject 

to copyright law. Any use without the 

consent of the publisher is not permitted 

and will be prosecuted. This applies to 

every conceivable form of reproduction. 

Copies and reprints can be ordered on 

request. Articles which are identified by 

name or which are to be assigned to an 

author by an abbreviation do not necessarily 

reflect the opinion of the editorial staff. 

Unsolicited manuscripts cannot be returned. 

If a manuscript is accepted by the editorial 

staff, publishing and copyright law as well 

as all rights for publication and distribution 

are transferred to the publisher. The 

publisher accepts no liability with regard 

to the facts set out in these articles. 

copyright © 2022 Dr. Harnisch Publications 

advertising index 

CERATIZIT Deutschland GmbH ................................inside front cover 

Aerotech, Inc. ..........................................................page. 11 

FILTECH ..............................................................page.13 

Lach Diamant Jakob Lach GmbH & Co. KG ............................. back cover 

Mikron AG, Division Tool ............................................front cover 


51

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