hpt 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

■ 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


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ISSN 2628-5444<br />

high precision tooling<br />

Machine Tools, PCD, PVD, CVD, CBN, Hard Metal <strong>2022</strong> – 4<br />

■ Productivity and sustainability are not mutually exclusive ■ Precision tool cutting edge cooling ■<br />

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

Accurate cutting edge<br />

cooling with the<br />

MaxiLock – S-DC<br />

DirectCooling (DC) system by CERATIZIT –<br />

now for turning holders!<br />

Three nozzles for the<br />

ultimate cooling effect<br />

- improved process security<br />

- higher service life<br />

Find out more at:<br />

cutting.tools/gb/en/direct-cooling<br />


CERATIZIT is a high-tech engineering<br />

group specialising in cutting tools and<br />

hard material solutions.<br />

Tooling the Future<br />


E-Mail puk@harnisch.com<br />

Internet www.harnisch.com<br />

Dr. Harnisch Verlags GmbH<br />

Eschenstraße 25<br />

90441 Nürnberg<br />

Telefon +49 (0) 911 2018-0<br />

Fax +49 (0) 911 2018-100<br />

E-Mail puk@harnisch.com<br />

Internet www.harnisch.com<br />


Materials: carbon steel, stainless steel,<br />

MIT MAGNETKUPPLUNG duplex stainless steel; others on request<br />

Differenzdruck-Begrenzungsventil<br />


www.klaus-union.com<br />



Modulares, axial geteiltes Gehäuse<br />

Werkstoffe: Kohlenstoffstahl, MORE INFO Edelstahl,<br />

Duplex Edelstahl; weitere auf Anfrage<br />

Dr. Harnisch Verlags GmbH<br />

Eschenstraße 25<br />

90441 Nuremberg, Germany<br />

Phone + 49 (0) 911 2018-0<br />

Fax + 49 (0) 911 2018-100<br />

www.klaus-union.com<br />

Axial split modular casing<br />

Differential pressure limiting valve<br />

Spalttopfausführungen:<br />

E metallisch / nicht-metallisch<br />

E einschalig / doppelschalig<br />

Containment shell executions:<br />

E metallic / non-metallic<br />

E single / double shell<br />

Wasser Abwasser Umwelttechnik<br />

Energie Öl Gas Wasserstoff<br />

Fahrzeugbau Schiffbau Schwerindustrie<br />

Chemie Pharma Biotechnik<br />

Lebensmittel- und Getränkeindustrie<br />

Water Wastewater Environmental Technology<br />

Energy Oil Gas Hydrogen<br />

Automotive Shipbuilding Heavy Industry<br />

Chemistry Pharmaceutics Biotechnology<br />

Food and Beverage Industry<br />

WANGEN_PuK_Titelseite_216x182.indd 1 24.01.<strong>2022</strong> 15:23:40<br />

Independent magazine for Pumps, Compressors and Process Components<br />

WANGEN_PuK_Titelseite_216x182.indd 1 24.01.<strong>2022</strong> 15:24:33<br />

Unabhängiges Fachmagazin für Pumpen, Kompressoren und prozesstechnische Komponenten<br />

editorial<br />


Eric Schäfer<br />

editor-in-chief<br />

Everything great in this world…<br />

…only happens because someone does more than he has to. This was<br />

once said by Hermann Gmeiner, the father of the SOS Children’s Villages.<br />

Doing more than necessary – this is what numerous companies are<br />

doing now with the aim of making their production more sustainable.<br />

CERATIZIT, for example, presented an ambitious sustainability strategy<br />

at AMB, International Exhibition for Metalworking. With this the<br />

company not only wants to become CO 2<br />

neutral by 2025, but also<br />

to be a leader in sustainability in the carbide and cutting tool industry.<br />

Sustainability was one of the three major topics at this year’s AMB.<br />

Further examples are shown in many articles in this issue, with which<br />

we once again present some trade show innovations. Tool manufacturers<br />

are increasingly paying attention to the efficient and careful use of<br />

resources in the supply chain.<br />

Companies like KYOCERA are working on efficient solutions such<br />

as determining ecological cutting values, material changes or digital<br />

solutions. After all, sustainability is playing an increasingly important<br />

role in productivity and future viability.<br />







Hygienisch fördern<br />

WANGEN VarioTwin NG<br />












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



The hygienic solution<br />

WANGEN VarioTwin NG<br />















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

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

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

The latter has been proven by LACH DIAMANT and Platinum Tooling,<br />

two companies that can point to their 100 th anniversary this year.<br />

That, too, is sustainable in a different way. Congratulations!<br />

Horst Lach regularly looks back on these 100 years in our<br />

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

material wood, and how its processing in furniture manufacturing<br />

as well as in the woodworking industry has changed through the use<br />

of diamond tools.<br />

Eric Schäfer<br />

editor-in-chief<br />

The independent media platform<br />

for energy supply, efficiency<br />

enhancement and alternative<br />

energy sources and storage<br />

Sustainable opportunities in<br />

process technology<br />

Circular economy in the industrial<br />

production process<br />

Topics H 2<br />

, Synthetic Fuels, Water,<br />

Solar & Photovoltaics, Wind Power,<br />

Bioenergy, Geothermal Energy,<br />

Battery Technology,<br />

System Integration and<br />

other alternative options<br />

Dr. Harnisch Publications<br />

Eschenstrasse 25<br />

90441 Nuremberg<br />

Dr. Harnisch Verlags GmbH · Eschenstr. 25<br />

Germany<br />

90441 Nürnberg · Tel.: +49 (0) 911 - 2018 0<br />

phone +49 - (0)911 - 2018 0<br />

info@harnisch.com · www.harnisch.com<br />

info@harnisch.com • www.harnisch.com

table of contents<br />

cover story<br />

High-performance titanium drilling, in one shot 6<br />

materials & tools<br />

Coated PCBN grade next generation technology 10<br />

Productivity and sustainability are not mutually exclusive 12<br />

Cutting insert “warns” before breakage 14<br />

Precision tool cutting edge cooling 15<br />

LACH DIAMANT looks back on 100 years – 14 th part<br />

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

μ-milling cutter – for high-precision requirements in mould making 21<br />

processes<br />

Retrofit unit for cryogenic process cooling<br />

Thomas Götz and Andreas Gebhardt, IPA 32<br />

New standards for eroding 35<br />

Making industrial production more flexible, more productive, and more sustainable 36<br />

machining center<br />

The leader in complete machining 38<br />

360° solutions for successful future manufacturing 39<br />

ANCA launches its premium, next generation machine range 40<br />

The answer to new requirements? New solutions 42<br />

The perfect machine for the entry-level segment 43<br />

components<br />

AMB premiere for the smart chuck jaw 44<br />

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

Filtration solutions that increase efficiency and sustainability 47<br />

special automation<br />

Showroom for the automation of tomorrow 48<br />

Well positioned at the SPS 50<br />

news & facts 22<br />

fairs 5, 22, 24<br />

impressum & company finder 51<br />

4 no. 4, November <strong>2022</strong>

fairs in alphabetical order<br />

AMB Stuttgart, Germany<br />

(September 10-14, 2024)<br />

bauma Shanghai, China<br />

(November 22-25, <strong>2022</strong>)<br />

CIMT Beijing, China<br />

(April 10-15, 2023)<br />

DEBURRING Karlsruhe, Germany<br />

EXPO (October 10-12, 2023)<br />

EMO Hanover, Germany<br />

(September 18-23, 2023)<br />

EPHJ Geneva, Switzerland<br />

(June 6-9, 2023)<br />

FABTECH Toronto, Canada<br />

(June 11-13, 2024)<br />

FEIMEC São Paulo, Brazil<br />

(May 9-13, 2023)<br />

GrindingHub Stuttgart, Germany<br />

(May 14-17, 2024)<br />

GrindTec Leipzig, Germany<br />

(March 7-10, 2023)<br />

Hannover fair Hanover, Germany<br />

(April 17-21, 2023)<br />

IMTS Chicago, USA<br />

(September 9-14, 2024)<br />

JIMTOF Tokyo, Japan<br />

(November 8-13, <strong>2022</strong>)<br />

LIGNA Hanover, Germany<br />

(May 15-19, 2023)<br />

MACH-TECH and Budapest, Hungary<br />

INDUSTRY DAYS (May 16-19, 2023)<br />

METALEX Bangkok, Thailand<br />

(November 16-19, <strong>2022</strong>)<br />

MOULDING Stuttgart, Germany<br />

EXPO (June 13-16, 2023)<br />

Wood TaiWan Taipei, Taiwan<br />

(April 20-23, 2023)<br />

SIAMS Moutier, Switzerland<br />

(April 16-19, 2024)<br />

sps Nuremberg, Germany<br />

sps on air digital (November 8-10, <strong>2022</strong>)<br />

TIMTOS Taipei, Taiwan<br />

(March 6-11, 2023)<br />

current status<br />

2024<br />

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

2023<br />

2023<br />

2023<br />

2023<br />

2024<br />

2023<br />

2024<br />

2023<br />

2023<br />

2024<br />

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

2023<br />

2023<br />

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

2023<br />

2023<br />

2024<br />

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

2023<br />

trade fair dates as by end of October <strong>2022</strong>; we are not responsible for reliability of these dates<br />

no. 4, November <strong>2022</strong><br />


cover story<br />

High-performance titanium drilling,<br />

in one shot<br />

Titanium is a high-performance material and poses a chip<br />

removing machining challenge. Also not all titanium is alike.<br />

Depending on whether it is pure titanium or alloyed titanium, the<br />

chip removing process behaviour differs. Mikron Tool has come up<br />

with different drill series that are perfectly tailored to the various<br />

titanium grades allowing to machine them safely with higher<br />

cutting performance results and longer tool life.<br />

Alberto Gotti PhD,<br />

head of research & development<br />

at Mikron Tool<br />

Titanium is highly popular in the medical technology field; due to its<br />

elasticity in conjunction with a high level of fatigue strength,<br />

titanium materials have unrivalled high bio-functionality<br />

Drilling into stubborn titanium is exceptionally<br />

challenging, partly because of the combination<br />

of high elasticity and tensile strength<br />

properties. The great toughness of this metal<br />

means that chip breaking is difficult to<br />

achieve. Due to the lower thermal conductivity,<br />

heat is not moved from the cutting area<br />

through the chip; but still needs to get rid of<br />

somehow. Also titanium has a propensity to<br />

create edge built-up which in turn can lead to<br />

higher levels of wear and reduce process reliability<br />

when drilling. Mikron Tool specializes<br />

in developing drilling technologies that are<br />

perfectly tailored to the material properties<br />

of pure titanium and titanium alloys. This is<br />

a complex task but then offers enormous production<br />

benefits for users.<br />


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

element in the continental crust. However, pure titanium is rarely found<br />

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

a procedure that was developed by William Justin Kroll, a metallurgist<br />

from Luxemburg, in 1930 for the complex production of titanium: it<br />

became possible to produce the metal for commercial applications<br />

thanks to the introduction of the industrial reduction of titanium<br />

(IV)-chloride with magnesium. The production process used here is<br />

extremely complex, as reflected by the very high price for titanium.<br />

Some call titanium a temperamental diva that screams when treated<br />

incorrectly. Titanium developed into an ultra-material for the industry<br />

due to its excellent properties. The application horizon is broad:<br />

aerospace, motor racing, medical and dental equipment, surgical<br />

orthopaedics and the jewellery and watch sectors all use it. Titanium<br />

is also ideal for eyeglass frames. In short, this metal is very popular in<br />

industry thanks to the broad market base.<br />

330.000 sh tn are processed every year.<br />

Titanium’s supernatural image is the<br />

reason for this figure.<br />

Rightly so because it is indestructible.<br />

It hardly weathers when it encounters<br />

oxygen because it is coated in a thin,<br />

transparent oxide layer. Even the most<br />

aggressive media, like acids, have very<br />

little impact on titanium. It is almost as<br />

light as aluminium, but much stronger,<br />

almost on a par with tempered steel. It<br />

is also biocompatible and anti-magnetic.<br />

6 no. 4, November <strong>2022</strong>

cover story<br />

figure 1<br />

Titanium: “Like drilling into rubber”<br />

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

at Mikron Tool. “Drilling titanium is much more challenging<br />

than milling; and it is even more difficult when the diameter-drilling<br />

depth ratio increases”. It becomes problematic<br />

above 3 x d. Titanium’s viscoelastic properties cause the drill<br />

to jam, which increases the pressure on the cutting edges.<br />

Material build-up on the cutting edges and margins increases<br />

the cutting forces which, in turn, can cause cutting edge<br />

breakout. Once the surface is compromised, even more material<br />

will build up and lead to higher friction. Also, the chip<br />

shape becomes problematic because the titanium chips tend<br />

to accumulate in the tip area and prevent smooth flowing of<br />

chips. In turn, this often leads to uncontrolled drill breakage.<br />

A further compounding factor are the high temperatures to<br />

which edges are exposed. From a temperature of 600 ° Celsius<br />

the cobalt binding matrix in the carbide substrate becomes<br />

‘soft’ and is no longer able to bind the hard tungsten carbide<br />

optimally. That leads to plastic deformation and micro-wear,<br />

and ultimately cutting-edge breakouts.<br />

Material-specific tools are the solution<br />

One remedy are cutting edges which need to be very sharp<br />

and very stable at the same time – a contradiction in itself.<br />

Mikron Tool has developed an ingenious specific cutting<br />

geometry that manages this balancing act and, as a result,<br />

cutting pressures can be reduced significantly. As described<br />

above, the heat needs to be moved from the machining area.<br />

The solution: two cooling channels with very large crosssections<br />

deliver large quantities of coolant through to the<br />

drill tip to guarantee constant cooling, including lubrication<br />

of the cutting edges. At the same time, the solid coolant<br />

jet flushes the chips through the polished flutes and prevents<br />

jamming chip backup. (figure 1)<br />

There is nothing new here, but: the patented special design<br />

of the cooling channels by Mikron Tool allows four times<br />

the amount of coolant quantity to be shot into the tool with<br />

constant pressure. This is a further key to success and stands<br />

for innovation in the thermal dissipation and chip removal<br />

technology.<br />

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

no. 4, November <strong>2022</strong><br />


cover story<br />

figure 2<br />

Also the flute profile helps significantly with the chip<br />

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

a carbide grade that combines wear resistance and fracture<br />

resistance strength. The coating is distinguished by its excellent<br />

wear and oxidization resistance, and as an addi tional<br />

benefit diminishes the tendency of material sticking.<br />

“Not all titanium is alike”, says Markus Schnyder, COO of<br />

Mikron Tool. “Anyone who wants to process this material<br />

efficiently needs to know it inside out. During our development<br />

work, we examined various titanium materials and established<br />

that the different titanium types differ greatly; this<br />

is highly relevant for the way it is machined in industrial production.<br />

Pure titanium (grade 1 – 4) stands out due to its high<br />

corrosion resistance, while it has lower mechanical strength”.<br />

The right drill for each grade of titanium<br />

Markus Schnyder: “Alloyed titanium (grade 5 and higher) is<br />

incredibly strong but has low ductility. We worked like crazy<br />

to master these differences with chip removal technology.<br />

Three years of meticulous development work lie behind us.<br />

Our passion and the insights we gained have led us to a perfect<br />

solution: two specific geometries, one for pure titanium grades<br />

and one for titanium alloys. Thus, we can guarantee perfectly<br />

controlled chip removal, high drilling speeds and precisely<br />

repetitive processes with optimum machining quality<br />

for these difficult titanium materials. The right and specific<br />

drill for each titanium grade. This is our answer for handling<br />

this complex and ‘divine material”.<br />

Crazy drill cool titanium – twice as fast<br />

The new Crazy Drill Cool Titanium series is available in a<br />

diameter range of 1.00 to 6.35 mm (.04" – .250"). Mikron<br />

Tool has developed short drills with 3 x d and drills with 6 x d<br />

for pure titanium (CrazyDrill Cool Titanium PTC) and<br />

drills with 6 x d and 10 x d in combination with a special pilot<br />

drill for titanium alloys (CrazyDrill Cool Titanium ATC).<br />

(figure 2)<br />

For the cost-effective production of titanium components,<br />

tools are required which are specially adapted to the material<br />

properties of the various titanium grades.<br />

Titanium material as well as the workpiece are expensive,<br />

which is why high process reliability and calculable tool<br />

life are so important. If the latter can be improved, so much<br />

the better. Mikron Tool’s new high-performance drills for<br />

titanium have up to three times longer tool life and work with<br />

twice the feed than current competitors. Another outstanding<br />

aspect: with the ATC-version drilling is completed in one<br />

shot, without multiple machining steps.<br />

Things are heating up in the Mikron Tool think tank;<br />

drill into titanium even more quickly and safely;<br />

twice as quick and 2 – 3 times longer tool life in<br />

combination with excellent process reliability<br />

The result is impressive and proves once again, that<br />

Mikron Tool is a technological leader and will defend its<br />

position by machining difficult materials successfully. “We<br />

love getting the best out of our tools for our customers.<br />

Nothing is too ‘crazy’ for us”, says Alberto Gotti.<br />

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

8 no. 4, November <strong>2022</strong>

Producing threads in high-tensile steels<br />

Top-class tap for difficult-to-machine steels<br />

materials & tools<br />

Machining high-tensile steels presents particular<br />

challenges, as the tool must also achieve a long tool life<br />

in addition to top process reliability and performance.<br />

When it comes to problems of producing threads in<br />

such demanding materials, the Hoffmann Group has<br />

now developed a new tap that easily masters this task:<br />

the GARANT Master Tap Steel HT.<br />

In the case of high-tensile materials such as Toolox and<br />

Hardox, blind hole threads can be produced up to a maximum<br />

thread depth of 2xD. For materials with a somewhat<br />

lower tensile strength, thread depths of up to 2.5xD in the<br />

blind hole version and of up to 3xD for through hole threads<br />

are also possible.<br />

Thanks to the strong spiral point, the through hole machine tap remains stable and reliable<br />

even when under high cutting force loads<br />

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

which can lead to break-away of the thread flanks<br />

This specialist in the thread production segment is made<br />

from a high-quality and rigid HSS-E-PM tool material and<br />

is protected against process heat by a hard and low-friction<br />

multi-layer coating. A special feature is that two different<br />

coatings are used per application in order to adapt the process<br />

even more effectively to meet various different requirements.<br />

The tap for blind hole production is therefore coated<br />

with titanium aluminium nitride (TiAIN), while the one<br />

for through hole production is coated with titanium carbon<br />

nitride (TiCN).<br />

The geometric feature of the cylindrically stepped guide<br />

thread is relied upon in order to avoid the risk of chip<br />

jamming during the production of blind hole threads – which<br />

can lead to break-away of the thread flanks in the case of<br />

high-tensile materials. The through hole tap, on the other<br />

0hand, remains stable and reliable even under high cutting<br />

force loads thanks to its strong and optimally crafted spiral<br />

point.<br />

With the new GARANT Master Tap Steel HT, M, MF and<br />

G threads can be produced both as blind hole and through<br />

hole threads. The taps with the M and MF design are manufactured<br />

only in the 6HX and 6GX tolerance, in order to counteract<br />

wear in case of abrasive materials. This results in reliable<br />

threads that are true to gauge being produced, and a long<br />

tool life. The GARANT Master product range was started<br />

by the Hoffmann Group 2015 aiming to provide particularly<br />

powerful and reliable tools for high-performance cutting.<br />

Since then, GARANT Master tools have opened up new performance<br />

classes, including the GARANT Master Steel HPC<br />

milling cutter, the GARANT Master Steel Feed and Speed<br />

solid carbide drills and the GARANT Master Steel Deep<br />

solid carbide deep hole drill. The product range now comprises<br />

a wide range of high-performance tools for applications such<br />

as drilling, milling and thread tapping in various materials,<br />

including steel, aluminium and stainless steel.<br />

further information: www.hoffmann-group.com<br />

no. 4, November <strong>2022</strong><br />


materials & tools<br />

Coated PCBN grade next generation technology<br />

Hardened steel turning<br />

Mitsubishi Materials has developed a new and<br />

innovative coated PCBN insert grade, BC8210. In<br />

doing so it has extended its comprehensive range of<br />

turning inserts. The grade incorporates the company’s<br />

state of the art coating technology that provides outstanding<br />

wear resistance, as well as providing a<br />

product that improves productivity and usability.<br />

The new grade is suitable for continuous through to light interrupted<br />

cutting. BC8210 exhibits excellent chipping, flank<br />

and crater wear resistance, thereby providing a stable machining<br />

process at high speed cutting conditions. A combination<br />

of the newly developed AlCrSiN-base coating that<br />

absorbs impacts, and the TiAlSiN-base coating which has<br />

excellent wear resistance, provides stability during continuous<br />

through to low interrupted cutting applications.<br />

At depths of cut up to 0.35 mm and at cutting speeds up to<br />

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

be covered by a single grade. This brings a simplification of<br />

choice for production and CNC programming and reduces<br />

inventory costs.<br />

High technology substrate and coating<br />

The new line of CBN inserts delivers a variety of performance<br />

and benefits through constant refinement and R&D work.<br />

This has created a new sintered substrate containing both<br />

micro and medium grain CBN particles, but with an ultra<br />

micro-particle binder. This new binding technology in the<br />

substrate provides ultra heat resistant and prevents sudden<br />

fracture by eliminating the potential for linear crack development.<br />

With the cutting forces being dispersed radially by<br />

this new binder formula, BC8210 excels when machining<br />

extremely hard steels. Additionally, this new substrate<br />

enables a wider range of applications, provides greater chipping<br />

resistance and wears less.<br />

This new technology has been applied to a specially developed,<br />

multi-layer PVD coating that the BC8210 grade utilises.<br />

This new coating includes a TiAlN bottom layer that greatly<br />

improves adhesion between the base layer and the CBN substrate<br />

and provides exceptional peeling resistance. Above this<br />

layer is an additional TiAlN layer that provides outstanding<br />

chipping and crater wear resistance. Together with a gold<br />

coloured, TiN top layer for easy identification of used edges,<br />

BC8210 achieves high performance, speeds and reliability<br />

over a wider range of hardened steel machining applications.<br />

Choice of chipbreakers<br />

BC8210 inserts are available with 4 different chipbreakers;<br />

the FS and GS types for general cutting, the GH for higher<br />

feeds and depths of cut and finally the TS type for light interrupted<br />

machining.<br />

TiN-coating<br />

AlCrSiN-base coating<br />

Gold colour aids easy identification<br />

of used edges<br />

strong resistance to chipping,<br />

absorbs impact forces<br />

TiAlSiN-base coating<br />

excellent wear resistance<br />

and abrasion resistant<br />

layer<br />

TiAlN-base coating<br />

PCBN sintered body<br />

improved strength of adhesion<br />

to the PCBN substrate<br />

prevents peeling<br />

exclusive BC8210<br />

sintered substrate<br />

further information: www.mmc-hardmetal.com<br />

10 no. 4, November <strong>2022</strong>

materials & tools<br />

Stable, process-safe and<br />

highly efficient<br />

CAN YOUR<br />


DO THIS?<br />

With the MultiEdge T90 PRO4 tangential corner and face milling<br />

cutter, LMT Tools is expanding its milling system for demanding<br />

cutting tasks.<br />

A high metal removal rate, great process reliability and economical operation:<br />

this is offered by the MultiEdge T90 PRO4 tangential corner and face milling<br />

cutter, which LMT Tools has expanded to include a highly efficient “porcupine<br />

mill” variant and cutting inserts with chip breakers. This is suitable for rough<br />

milling and semi-finishing operations on machine components such as pump<br />

housings, machine frames and guide rails.<br />

The new porcupine cutter<br />

variant of the MultiEdge<br />

T90 PRO4 from LMT Tools:<br />

process-reliable, powerful<br />

and efficient for roughing and<br />

semi-finishing operations<br />

For cast iron, steel and stainless steel<br />

“New to the MultiEdge T90 PRO4 are cylindrical milling cutters, which are<br />

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

explains Hanjo Gissler, senior product manager for milling. The inserts allow<br />

cutting depths of up to 11.5 mm and are suitable for machining cast iron<br />

(ISO-K materials) as well as steel (ISO-P) and stainless steels (ISO-M).<br />

The inserts, manufactured using the press-to-size process, have four usable<br />

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

mounting in the milling body, they operate with very low vibration.<br />

The tangential installation position enables a particularly favorable ratio of contact<br />

surface and clamping force and thus maximum stability. “Even at a high<br />

chip removal capacity, the tools are thus extremely process-reliable,” emphasizes<br />

Gissler. Their positive rake angle also results in excellent cutting performance<br />

and thus low power consumption on the machine.<br />

Significantly reduced cycle times<br />

Another factor for increasing efficiency is the optimum ratio of tool diameter to<br />

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

enormous metal removal rates are thus possible. “This shortens cycle times and<br />

reduces overall process costs,” says Hanjo Gissler. This has also been shown<br />

by the first practical applications of the new tools. “A mechanical engineering<br />

customer from France was able to significantly reduce both its tooling costs and<br />

machining time by using the MultiEdge T90 PRO4,” Gissler relates, “the latter<br />

by a spectacular 80 %.”<br />

PRO165SV is shown lifting<br />

a 5-gal (18.9 l) water jug,<br />

which is 41.7 lbs (18.9 kg).<br />

The PRO-SV from Aerotech is:<br />

• Currently the most precise lift table on<br />

the market<br />

• The only lift table with long travel and<br />

up to 60 kg moving mass<br />

• Easy to assemble with dynamic<br />

performance<br />

The PRO-SV is ideal for:<br />

• Height-limited applications<br />

• Combining several positioning tables<br />

on top of each other<br />

Specific applications:<br />

• Sample positioning in beamline/<br />

synchrotron positioning<br />

• Wafer inspection<br />

• Surface measurement<br />

further information: www.lmt-tools.com<br />

See for yourself at<br />


materials & tools<br />

Productivity and sustainability are not<br />

mutually exclusive<br />

The KYOCERA Group presented<br />

a variety of cutting solutions<br />

for industrial machining<br />

and manufacturing at the AMB<br />

exhibition in Stuttgart. As well<br />

as top innovations for the construction<br />

of electric vehicles, these<br />

also include solutions for energy<br />

production (such as wind power<br />

technology).<br />

Key words like reliability, precision,<br />

versatility and sustainability are on the<br />

focus: as a tool manufacturer, Kyocera<br />

pays particular attention to the efficient<br />

and careful use of resources<br />

in the supply chain. In addition the<br />

company is pushing to find more efficient<br />

solutions like identifying economical<br />

cutting values, material<br />

changes or digital solutions, in order<br />

to operate more sustainably.<br />

Minimising CO 2<br />

emissions<br />

The KYOCERA Industrial Tool Group<br />

is pursuing the long-term goal of reducing<br />

CO 2<br />

emissions within the<br />

whole supply chain in the cutting tools<br />

sector. Individual steps range from<br />

product development to purchasing, distribution, sales, processing,<br />

resource recovery and re-use, through to disposal.<br />

Five key aspects for climate neutrality in cutting tools<br />

Through the ever-changing world, as well as the associated<br />

new set of challenges, the company expands its tool and service<br />

portfolio, and pursues an even more economical and<br />

sustainable approach. Additionally, the increase in productivity<br />

lowers CO 2<br />

emissions. For example, a CO 2<br />

emission<br />

calculator helps this. The tool calculates the saving potential<br />

in machining through the tool selection and individual<br />

parameters.<br />

Stator housing units made of aluminium with various tools<br />

that are necessary for the construction of such a housing unit<br />

(PDK stepped reamers; boring tools; milling cutters)<br />

Highly efficient processing to save energy<br />

High-quality processing with new tool solutions allows<br />

new ways of thinking. Here, for example, hidden processing<br />

errors, can be uncovered, eradicated and thus resources<br />

can be saved. In this context the High Feed Milling Series<br />

(MFH) has been providing immense savings in production<br />

worldwide since years. Kyocera now presented an updated<br />

lineup at AMB with cutting depths of up to 2.5 mm. In short,<br />

this means that there is an enormous increase in productivity<br />

through the development of high value-added tools. At AMB<br />

it was also possible to view tool portfolio extensions for nextgeneration<br />

components and for environmentally friendly<br />

industrial components.<br />

12 no. 4, November <strong>2022</strong>

materials & tools<br />

Use of DX technology<br />

“From a world of reflecting after processing to a world where we can see things<br />

before processing” – this is a quote from the Kyocera headquarters in Kyoto<br />

regarding digital transformation. The goals of this transformation are to reduce<br />

machining times, optimise machining conditions, identify machining problems<br />

and take countermeasures in advance. In order to actually implement these<br />

goals the DX technology offers a dynamic and sustainable range of tools through<br />

analysis technologies. An example of this is the AI-based wear analysis assistant.<br />

The type of wear is determined via photo upload of the indexable insert. The tool<br />

will first be launched in Japanese and soon will be available in other languages.<br />

Easy solutions for electric vehicles<br />

In order to be able to generate a long range and thus attractiveness with heavy<br />

electronic vehicle batteries, a comprehensive weight optimisation of the structural<br />


February 14 – 16, 2023<br />

Cologne – Germany<br />

The Filtration Event<br />

www.Filtech.de<br />

Platform<br />

for your<br />

success<br />

Easily combinable compartments allow for<br />

sufficient space in the smallest of spaces<br />

components is essential. KYOCERA Unimerco has been working with specially<br />

developed tools for aluminum with low silica content for decades. In this way<br />

not only efficiency and dimensional accuracy are taken into account, but also<br />

the demand for the lowest possible burr formation, especially for thin-walled<br />

structures. Here Kyocera’s standard tools are also used as special tool solutions<br />

with PCD cutting edges that meet the high and strict requirements of the<br />

automotive industry.<br />

RE•NEW TM program expansion<br />

KYOCERA Unimerco’s concept for tool maintenance offers a lot more than<br />

just the regrinding of tools. KYOCERA Unimerco established its first regrinding<br />

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

which is constantly improved to meet current standards. Tools with the predicate<br />

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

tool. Up to 75 % savings on processing costs are thus possible. The returned tool<br />

will not only have the same quality, but also the same performance features.<br />

Delivers<br />

solutions for<br />

current<br />

and future<br />

challenges<br />

From October <strong>2022</strong> on it will also be possible to overhaul the MagicDrill DRAs<br />

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

course under the promise of RE•NEW TM .<br />

further information: www.kyocera.co.uk<br />

Your Contact: Suzanne Abetz<br />

E-mail: info@filtech.de<br />

Phone: +49 (0)2132 93 57 60

materials & tools<br />

Risk detected and averted:<br />

Cutting insert “warns” before breakage<br />

Machining steel is anything but simple. Experienced<br />

machining specialists all agree on this and are<br />

open to any solution that helps them turn ISO-P steel.<br />

That is why CERATIZIT has put its turning grades<br />

to the test and “refined” them where necessary – with<br />

long-term success.<br />

ISO-P steels are by far the biggest material group in metal<br />

machining as it includes materials such as ductile, low-carbon<br />

steels right through to high-alloy steel grades. Added<br />

to this are variations in hardness, application types and<br />

machining conditions during turning operations. To make<br />

choosing an appropriate indexable insert grade easier, the<br />

turning specialists at CERATIZIT have developed their own<br />

indexable insert grades and tailored them to the enormous<br />

variety of ISO-P materials.<br />

For steely types and tough nuts<br />

“The indexable inserts for our grades CTCP135-P, CTCP125-P<br />

and CTCP115-P have significantly boosted output in comparison<br />

with their predecessors: 20 % longer service lives<br />

speak for themselves and make our turning tools even more<br />

appealing,” says Stefan Karl, product manager Cutting Tools<br />

at CERATIZIT. Anyone who fails to look closely enough at<br />

alternatives and best-practice when selecting an indexable<br />

insert grade is squandering major potential savings.<br />

To enhance productivity for its customers CERATIZIT has<br />

rethought its new turning grades, from the substrate to the<br />

geometries, right through to the Dragonskin coating – for optimal<br />

process security and hardness of cutting edges so that<br />

they can withstand the extreme temperatures in the cutting<br />

zone without plastic deformation. This ensures that they are<br />

prepared for every challenge, regardless of whether extremely<br />

hard or tough materials need to be machined.<br />

Dragonskin produces hard facts<br />

The innovative Dragonskin coating is crucial to the performance<br />

capability of the new steel turning grades. Its optimised<br />

structure is designed to increase tool life and reduce<br />

machining time. Mechanical post-treatment enables<br />

CERATIZIT to achieve the layer surface’s unique state of<br />

residual stress, which pays off in terms of increased process<br />

security, especially in large-scale production.<br />

ISO-P steel is not so tough: the new CTCP135-P, CTCP125-P<br />

and CTCP115-P steel turning grades are specially designed<br />

for this material<br />

Wear can be detected in good time thanks to the<br />

indicator layer of the new Dragonskin coating<br />

The CTCP115-P (ISO P15) grade is particularly suitable for<br />

smooth cuts with stable cutting conditions and continuous<br />

cuts. CERATIZIT has also provided grades CTCP125-P (ISO<br />

P25) for turning operations from finishing to rough machining<br />

and CTCP135-P (ISO P35) for cuts in unstable and difficult<br />

conditions.<br />

Process-secure thanks to wear detection<br />

When approaching the end of its life cycle, every cutting<br />

insert experiences a drop in performance. If this is detected<br />

too late, the machining quality may already have been<br />

reduced significantly. “This is even worse if the tool is pushed<br />

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

this case the defective cutting insert is the least of your problems.<br />

The damaged workpiece presents a much more serious<br />

issue,” says Stefan Karl knowingly. However, if the user<br />

identifies the extent of wear directly using the new indexable<br />

insert indicator layer, they can replace it in a timely manner.<br />

“A lot of our customers wanted this feature, which is why<br />

we have incorporated it into the latest generation of our steel<br />

turning grade in the form of the special Dragonskin coating<br />

– for stable and conflict-free processes!”<br />

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

14 no. 4, November <strong>2022</strong>

Turns on, stays cool:<br />

Precision tool cutting edge cooling<br />

materials & tools<br />

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

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

now also with the MaxiLock-S DC turning tools holder<br />

What is good for the inside can also be good for<br />

the outside. That is what the development specialists at<br />

CERATIZIT thought when upgrading the tried-andtested<br />

MaxiLock-S turning tool holder to the Direct-<br />

Cooling holder. Two nozzles apply coolant now directly<br />

to the cutting edge – enabling tools to give wear the<br />

cold shoulder.<br />

More is more – this principle still dominates coolant delivery<br />

but change is coming. With a focus on sustainability and<br />

the efficient use of resources, the smart successors to flood<br />

coolant/lubrication are already waiting in the wings. Accurate<br />

not liberal, precisely applied not spurted on – these are the<br />

arguments in favour of the DirectCooling (DC) system from<br />

CERATIZIT that bring a minimalist approach to machining<br />

companies.<br />

Precisely on the hot zone<br />

The typical scenario in a turning center is that a hose distributes<br />

the coolant extensively on the machining area. The new<br />

MaxiLock-S DC turning tool holders, which supplement the<br />

DirectCooling (DC) system, provide a different way of doing<br />

things. The holders feature two internal holes ensuring that<br />

the coolant is applied precisely to the cutting edge, with one<br />

hole targeting the rake face from above and the other the<br />

flank from below, proving that not all good things come from<br />

above. By contrast, flank cooling boosts the service life by<br />

60 % compared with cooling exclusively on the rake face.<br />

DC can also now do it<br />

“We wanted to take what has since became the norm for<br />

grooving holders and apply it to our turning tool holders<br />

for external turning applications too. This resulted in the<br />

MaxiLock-S DC range, which allows customers to boost<br />

both general process security and cutting values thanks<br />

to targeted cooling. Compared with conventional cooling,<br />

DirectCooling achieves service life improvements of around<br />

65 %, regardless of material and machining application,”<br />

explains Stefan Karl, product manager Cutting Tools at<br />

CERATIZIT. Also the insert seat has been reworked. This<br />

makes it possible to clamp the turning indexable insert with<br />

even more stability, which reduces wear on the cutting edges<br />

and creates better surfaces on the workpiece.<br />

DirectCooling can be used for any application and works<br />

from a coolant pressure of just 10 bar. The coolant must only<br />

be transferred via the turret of the turning center or turningmilling<br />

center, which is the case in most recent machines.<br />

“The higher the pressure, the better chips are broken and<br />

cleared away. This is particularly beneficial to those who<br />

machine steels and is also excellent in combination with our<br />

new ISO-P indexable insert. However, the MaxiLock-S DC<br />

is just as comfortable on stainless and difficult-to-machine<br />

materials,” says Stefan Karl.<br />

Flexible and stable with a system<br />

Interference contours are a common problem during<br />

machining, but not for the holders from the DirectCooling<br />

series. Their lengths have all been ideally matched to one<br />

another and also offer optimal stability and unlimited flexibility.<br />

The nozzles of the new MaxiLock-S DC turning tool<br />

holder can also be replaced – for long, accurate cooling.<br />

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

no. 4, November <strong>2022</strong><br />


materials & tools<br />

New coating<br />

With the new RC2 and RC4 coatings, Paul Horn<br />

GmbH exhibited new developments in the field of highperformance<br />

tool coatings. The high toughness and<br />

hardness allow the machining of steels at high cutting<br />

speeds and lead to a significant increase in tool life.<br />

The high temperature resistance enables productive use in<br />

dry machining as well as with minimum quantity lubrication.<br />

Numerous tool systems are available from stock with<br />

the new HiPIMS coating. In-house coating enables fast<br />

delivery times even for special tools.<br />

With the new RC2 and RC4 coatings, Paul Horn GmbH<br />

is exhibiting new developments in the field of<br />

high-performance tool coatings<br />

Horn is constantly investing in new and modern technologies.<br />

In 2015 the company CemeCon delivered the world’s<br />

first of three HiPIMS systems to Horn. The High Power Impulse<br />

Magnetron Sputtering technology brings specific advantages<br />

and new possibilities in the coating of precision<br />

tools. It enables the build-up of dense, compact coatings that<br />

are very hard and tough. The coatings have a homogeneous<br />

structure and uniform coating thickness even if the tool<br />

geometry is complex. Research and development of new and<br />

existing coatings and technologies is a central component of<br />

success. Horn employs a team of engineers who work exclusively<br />

on this subject. Since in-house coating started, research<br />

and development projects have been carried out in cooperation<br />

with equipment manufacturers.<br />

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

Horn is constantly investing in new and modern technologies<br />

16 no. 4, November <strong>2022</strong>

Groove and cut-off milling system<br />

materials & tools<br />

Paul Horn GmbH presented<br />

a completely new generation<br />

of groove and cut-off milling<br />

system at AMB <strong>2022</strong>. The newly<br />

developed tool system enables<br />

highly economical and productive<br />

milling performance. Each<br />

precision-ground indexable<br />

insert offers four usable cutting<br />

edges. This means that the<br />

user no longer needs different<br />

inserts to equip the milling cutter<br />

body.<br />

Horn offers the positive inserts<br />

with round chip breaker groove in<br />

the new grade RC4G. This grade<br />

enables high cutting performance<br />

during the milling process. The<br />

M475 system complements the existing<br />

Horn milling systems M310,<br />

382 and 383. The special surface<br />

treatment of the milling cutter bodies<br />

offers a high level of protection<br />

against abrasion from chips.<br />

The cutter bodies are available<br />

from stock as side milling cutters,<br />

shell milling cutters and screw-in<br />

milling cutters. The shell and<br />

screw-in milling cutter variants are<br />

equipped with an internal coolant<br />

supply. Horn offers the side milling<br />

cutters in diameters from 80 mm to<br />

200 mm. The cutting and grooving<br />

width is optionally 5 mm (0.197“),<br />

6 mm (0.236“) or 8 mm (0.315“). As<br />

shell mills, the tools are available in<br />

diameters from 63 mm (2.480") to<br />

200 mm (7.874"). The groove widths<br />

are the same as for the side cutter<br />

variant. The screw-in cutters are<br />

available for groove widths from<br />

5 mm (0.197") and diameters from<br />

40 mm (1.575") to 63 mm (2.480")<br />

as standard. The effective number<br />

of teeth of all variants depends on<br />

the respective diameter. For example,<br />

it is zeff = 2 for the 40 mm<br />

(1.575") diameter shell mill and<br />

zeff = 13 for the 200 mm (7.874")<br />

side cutter. The large number of effective<br />

cutting edges also contributes<br />

to the economic efficiency of<br />

the new M475 milling system.<br />

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

The precision-ground indexable insert offers four usable cutting edges<br />

The completely new developed tool system M475 enables<br />

highly economical and productive milling performance<br />

no. 4, November <strong>2022</strong><br />


materials & tools<br />

LACH DIAMANT looks back on 100 years – 14 th part<br />

Poly – poly – or what?<br />

Yeah, here I come…<br />

the diamond as a tool in the furniture industry,<br />

as well as in wood and plastic processing industries<br />

Yesterday evening, in the middle of the daily news<br />

show, I jumped up spontaneously – and my wife noted<br />

with surprise that I suddenly grabbed paper and pen.<br />

“Yeah, here I come...” was what I jotted down as the<br />

title of my next “Poly – poly or what?” article.<br />

No worries, I will not write down my full life story, but I<br />

might have been inspired by a report on TV: “Despite Corona,<br />

the German furniture industry, especially kitchen furniture,<br />

is doing well.”<br />

That comes as no surprise, considering the lockdowns,<br />

home office and confinement to the privacy of our homes.<br />

On top of that, no vacations, no money spent in restaurants<br />

and bars. A continued focus on our own home surroundings<br />

and constant activities in the kitchen inspire a change in<br />

furniture.<br />

Obviously – and quite natural for Horst Lach – diamonds<br />

come into the mind, both in a narrower and in a broader<br />

sense, and in connection with the machining of wood and<br />

plastic composites.<br />

Doing so, I do not yet know who my readers will be, so<br />

please forgive me for this. Our example today, the diamond,<br />

is by now known as dia tool within the industry.<br />

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

it already started approximately 50 years ago, in 1973,<br />

when General Electric was the first manufacturer to offer<br />

polycrystalline diamonds under the trademark of “compax”.<br />

A development I experienced personally, and which I can<br />

only share due to my advanced age and my own profession.<br />

Therefore, I can understand how, during a continued<br />

industrial revolution, an ever-increasing demand for mass<br />

production ignited the desire for abrasive cutting tools with<br />

ever-greater stability – in the end for the hardest of all things –<br />

DIAMOND. And this not only in the metal industry, and in<br />

machine construction, but also for machining of all wood<br />

materials.<br />

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

previously used high-speed steel (HSS) for the first time – the<br />

very name of a trademark of Krupp company in Essen reflected<br />

this “desire” for the hardest of all things – Widia<br />

(based on the German term “wie Diamant” = like diamond).<br />

And then – just when “hard metal” had established itself<br />

in the market, due to a parallel and fast-paced development<br />

of resin bond diamond grinding wheels – out of the<br />

blue, a manufacturer named Lach-Spezialwerkzeuge GmbH<br />

(LACH DIAMANT) presented a complete dia tool and saw<br />

programme for the wood and plastic processing industry at<br />

LIGNA 1979.<br />


at LIGNA 1979<br />

18 no. 4, November <strong>2022</strong>

materials & tools<br />


at LIGNA 1979<br />

Under the slogan “Your Way to Diamond Economics”, Lach-<br />

Spezial offered diamond tools with tool times far-superior to<br />

carbides (up to several hundred times), according to the regulations<br />

of the trade association’s “BG-Test and BG-Form”. Despite<br />

the initially high tool price, diamond tools proved to be<br />

efficient from the start on – straight-edged dia cutting edges<br />

were priced at 70-80 DM (Deutsche Mark) per mm, profile<br />

cutting edges at 100 DM (Deutsche Mark) per mm. Thanks<br />

to a close collaboration between LACH DIAMANT and<br />

General Electric, the prices for polycrystalline diamond inserts<br />

could be lowered significantly during the 1980’s. The<br />

development of new markets for PCD tools in the aviation<br />

and composite industry followed.<br />

As a typically medium-sized industry, furniture and kitchen<br />

furniture manufacturers took the lead in utilizing these versatile<br />

and cost-reducing production and design options and<br />

became the top customers for polycrystalline diamond cutting<br />

tools and saws; even ahead of the aluminium-machining<br />

automobile industry. At that time, the control technology<br />

of wood working machines was superior to controls of<br />

metal working machines, e.g., through the early switch from<br />

numeric (NC) to CNC controls.<br />

However, I should not forget to mention that not only furniture<br />

manufacturers profited from the new cutting material<br />

diamond – but also their employees. For example, now it was<br />

no longer required that a master craftsman had to be present<br />

for changing the tool during each shift in a 3-shift operation,<br />

a common practice for edging machines. Without any resharpening,<br />

the diamond tool would run for 3 to 6 months!<br />

From the beginning to the end of its tool life, there was no<br />

loss in sharpness, which proved to be a sales-promoting factor<br />

and a special advantage, especially for decoratively coated<br />

MDF boards (medium-density fibreboards).<br />

During a visit in the USA – after founding LACH DIAMOND<br />

INC. in Grand Rapids, Michigan – I witnessed the production<br />

of a massive, 40 mm thick, 1.5 m-diameter oak table top<br />

in one of the larger “furniture shops”. Two very muscular<br />

men had to use all their strength to circle this table top with<br />

a vertical Knoevenagel milling cutter. I will never forget this<br />

image. Months later, the new diamond tool allowed for only<br />

one man to do the same job without any pause or break, and<br />

without the previous struggle.<br />

Diamond<br />

tools with<br />

tool times<br />

far-superior<br />

to carbides<br />

However, I must admit that the respective workers were<br />

not that grateful to me and did not look at me that friendly;<br />

as I found out afterwards, their heavy labour bonus had<br />

been cut.<br />

Horst Lach<br />

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

no. 4, November <strong>2022</strong><br />


materials & tools<br />

New cutting materials for reaming and fine boring,<br />

quickly available MN reamers<br />

MAPAL presented at AMB the two new cutting<br />

materials HP016 and HP018. They are specially<br />

designed for the particular requirements of reaming<br />

and fine boring high-alloy and stainless steels as well<br />

as cast steel and hardened steel.<br />

The HP016 cutting material is suitable for all machining<br />

operations with a slightly interrupted cut, while the HP018<br />

cutting material is used for continuous cutting conditions.<br />

Both are based on a silicon doped PVD coating on two different<br />

carbide grades with low cobalt content, which stands for<br />

extreme wear resistance and high dimensional accuracy.<br />

The new cutting materials will be used for the market<br />

launch in the reamers of the MN series, among others. These<br />

tools stand for the very highest accuracies, can also be used<br />

optimally for hard reaming and for reaming stainless steel<br />

thanks to the new cutting materials and are now available<br />

within ten working days. They function according to the<br />

“MAPAL principle” – with one indexable insert and guide<br />

pads arranged around the circumference, which are made of<br />

carbide, cermet or PCD depending on the application.<br />

E-mobility: basic, performance and expert solutions<br />

Tool solutions for e-mobility are of particular importance<br />

in the automotive sector. For demanding components that<br />

will be produced in high quantities, MAPAL presents different<br />

machining levels: Basic, Performance and Expert. The<br />

new classification describes the different machining solutions<br />

depending on the quality requirements, number of units and<br />

investment. The Performance Line is aimed at series production<br />

and focuses on machining with special tools. It is mainly<br />

used when new components are to be produced efficiently<br />

and economically on existing systems.<br />

FaceMill-Diamond-ES and NeoMill-T-Finish<br />

increase economic efficiency in aluminium milling<br />

MAPAL expanded its aluminium milling programme with<br />

two new products. The FaceMill-Diamond-ES is a versatile<br />

all-rounder that ensures high economic efficiency and sustainable<br />

process reliability in demanding production conditions<br />

with smaller quantities and changing component types.<br />

The indexable insert milling cutters of the new NeoMill-<br />

T-Finish series provide a significant increase in the economy<br />

and efficiency of finish machining in series production. The<br />

finish milling cutter with exchangeable inserts functions according<br />

to the plug & play principle: customers change the<br />

inserts directly on site without having to adjust them afterwards.<br />

In addition this also means that fewer tool bodies have<br />

to be kept in stock.<br />

The new HP016 and HP018 cutting materials from MAPAL<br />

are specially designed for the particular requirements of<br />

reaming and fine boring high-alloy and stainless steels<br />

as well as cast steel and hardened steel<br />

The “Performance” tool package for machining stator housings<br />

for electric motors is optimised for medium production<br />

quantities; picture: the machining solution with HSK-63<br />

What makes the new milling cutter unique is a patentpending<br />

system of insert arrangement, which results in a<br />

homogeneous wear pattern of the cutting edges, longer tool<br />

life and thus a low cost per part.<br />

Titanium milling:<br />

NeoMill-2-HiFeed90 + OptiMill-Tro-Titan<br />

The tool programme for titanium machining is expanded by<br />

two efficient milling tools. The five-edged trochoidal milling<br />

cutter OptiMill-Tro-Titan is characterised by maximum<br />

metal removal rate and shines with excellent surfaces due<br />

to unequal spacing and unequal pitch of the cutting edges.<br />

It is designed for trochoidal milling in partial cutting, trimming<br />

and for cutting depths up to 3xD. The new radial insert<br />

milling cutter NeoMill-4-HiFeed90 will be available as<br />

an end mill, screw-in milling cutter and milling cutter head<br />

from January 2023. The universally applicable high feed<br />

milling cutter stands for high productivity and is characterised<br />

by the highest stock removal rates, very high feed rates<br />

and large chip depths.<br />

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

20 no. 4, November <strong>2022</strong>

materials & tools<br />

μ-milling cutter –<br />

for high-precision requirements in mould making<br />

Mould making plays a key role in many industries.<br />

Mould makers place high demands on cutting tools –<br />

after all, they are a key component in ensuring product<br />

quality. This is why Gühring presented a new milling<br />

cutter range for high-precision finishing requirements<br />

at AMB <strong>2022</strong>.<br />

The combination of new geometry, adapted coating system<br />

and ultra-hard substrate makes the high-precision milling<br />

cutters so successful when used in hardened tool steel.<br />

Maximum angular and fit accuracy<br />

Whether plastic, metal, glass or chocolate – moulding is what<br />

turns raw materials into products. Because these moulds produce<br />

the surfaces of the finished components, maximum precision<br />

is required here: only a perfectly manufactured mould<br />

can produce a final product with tolerances and surfaces that<br />

meet the required quality without reworking. For perfect part<br />

quality, mould makers rely on tools that guarantee process reliability,<br />

precision and repeatability. The Swabian tool manu -<br />

facturer Gühring meets precisely these requirements with<br />

a new range of high-precision milling cutters: the μ-precise<br />

solid carbide milling cutters have a stable core geometry and<br />

an optimised flute profile. Both reduce displacement during<br />

milling and ensure stability which is reflected in a very high<br />

contour accuracy. This makes the tools suitable for finishing<br />

high-precision fits and guides with exact angular accuracy.<br />

Safe chip removal during the milling process was another<br />

focus during tool development as a basic requirement for<br />

good surfaces. The structural dimensions and neck transition<br />

geometries of the new milling cutters have therefore been<br />

optimised for use in deep and narrow contours. All micro<br />

With the new G-mold μ tool range all milling<br />

processes in mould making can be covered<br />

milling cutters in the new range also consist of revolver<br />

blanks with GühroJet periphery cooling. With this innovative<br />

technology for internal cooling, chips are removed directly<br />

and safely from the machining zone by air, minimum<br />

quantity lubrication (MQL) or cooling lubricant.<br />

Harder substrate, extremely smooth layer<br />

Because tool and mould making involves machining highstrength<br />

and hardened steels, Gühring has adapted its carbide<br />

substrate to these materials with the new high-precision<br />

milling cutters: the cutting material is now around 200 HV<br />

harder and finer-grained. This ultra-hard solid carbide substrate<br />

guarantees very good edge stability and thus processreliable<br />

service life in hard machining. The precision blanks<br />

also have optimised shaft tolerances in the h5 range and are<br />

μ-precise in diameter, concentricity and roundness. The radius<br />

tolerances are even in the range of +- 5 μm. The coating system<br />

has also been specially adapted for mould making: a<br />

Perrox coating produced using the HiPiMS process makes<br />

the tool surfaces extremely smooth and therefore very resistant<br />

to wear. Thanks to this combination of carbide, coating<br />

and geometry, the new high-precision milling cutters promise<br />

a significant increase in performance – both in soft and harder<br />

materials up to 65 HRC and even in high-alloyed or powder<br />

metallurgically manufactured tool steels.<br />

Every milling application covered<br />

With its new G-Mold μ tool range, Gühring can now cover<br />

all milling processes in mould making. The solid carbide<br />

full-radius milling cutter “G-Mold μ65 B”and the highprecision<br />

torus cutter “G-Mold μ65 T” are perfect for copy<br />

milling and finishing of moulds and mould inserts made of<br />

hardened steel up to 65 HRC. The cylindrical high-precision<br />

finishing cutters “G-Mold μ65 F” for hardened workpieces<br />

and “G- Mold μ48 F” for soft workpieces enable the optimal<br />

angular accuracy and exact fits when finishing guides and<br />

pockets in moulding plates. The new μ-precise micro milling<br />

cutter “MikroMill μ55 U”meets high demands in the micro<br />

range: very high-quality surfaces can be achieved with<br />

the tightest tolerances and precise concentricity. An FEMoptimised<br />

radius angle transition also ensures maximum<br />

radial rigidity and low displacement during micro-milling.<br />

The innovative GühroJet internal cooling increases the<br />

service life of the tool and ensures process reliability.<br />

The new range offers a high degree of flexibility with over<br />

350 different dimensions, a wide range of full or corner<br />

radii as well as corner chamfers and different versions for<br />

hard and soft materials. Because quality counts above all in<br />

addition to quantity, the tool manufacturer has invested specifically<br />

in specialised production and measuring technologies<br />

at its site in Germany – for tools that customers in tool<br />

and mould making can rely on.<br />

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

no. 4, November <strong>2022</strong><br />


news & facts<br />

fairs<br />

Filtration in machining processes<br />

For health, safety, and efficient plant engineering<br />

Avoiding contamination, ensuring quality, safety, and<br />

health: filtration plays a decisive role in the processing<br />

of materials. Visitors to FILTECH will gain insights<br />

into all areas of filtration and separation of all types<br />

of media. The combination of trade show and congress<br />

offers everything they need for efficient filtration<br />

in their processes. The next FILTECH will take place<br />

February 14 to 16, 2023.<br />

Whether metals, glass, or ceramics: chips, dusts, and mole<br />

cular pollutants endanger the health of employees and the<br />

environment, but also the equipment. In many primary and<br />

secondary processes, filtration processes therefore play a<br />

decisive role in ensuring the quality of the product. Separation<br />

technology is also crucial for long service lives of the<br />

tools and equipment used. Above all, clean ambient air must<br />

be ensured for the health of the personnel.<br />

Especially in metal processing contamination of the materials<br />

can occur quickly. In forging, plasma or laser cutting<br />

and engraving, dry, clean, and oil-free air ensures quality,<br />

precision and economy. Air filters increase the service life of<br />

equipment and also determine compliance with applicable<br />

regulations and laws, for example with regard to CO 2<br />

emissions.<br />

Filters are also used in cooling and heating processes or<br />

in laser beam path purging.<br />

Equipment and components, services, and know-how for<br />

the diverse filtration processes in the processing of metals,<br />

glass, ceramics and other materials are offered by FILTECH<br />

exhibitors. At the combination of trade show and congress,<br />

visitors receive industry-specific expertise and opportunities<br />

for personal exchange about filtration and separation of all<br />

types of media.<br />

Focused trade fair with over 440 exhibitors<br />

From February 14 to 16, 2023, FILTECH will once again open<br />

its doors to visitors at the exhibition center in Cologne, less<br />

than a year after the previous date in spring <strong>2022</strong>. Due to the<br />

Corona pandemic it was necessary to deviate from the usual<br />

one-and-a-half-year interval. “The innovative power of the<br />

filtration industry is very high”, explains Suzanne Abetz<br />

from organizer FILTECH exhibition Germany. “At FILTECH<br />

2023 the trade audience will once again be presented with<br />

numerous innovations – also from many new exhibitors who<br />

are taking part for the first time.”<br />

Visitors will be offered a wide range of products and<br />

services: in addition to separation and separation technology,<br />

the program also includes measurement technology, ana<br />

lytics and laboratory supplies, as well as news from science<br />

and research. Industry giants will be represented as well<br />

as specialists and numerous research and development<br />

institutes.<br />

Since 2020 the desire for clean, hygienic ambient air has<br />

risen sharply, not only in production, numerous exhibitors<br />

are also focusing on products such as stationary air cleaners<br />

and systems in a wide variety of dimensions. HVAC systems<br />

from the exhibitors achieve separation rates of over 99.9 %<br />

and can support operators with energy-efficient solutions for<br />

all applications in operational buildings.<br />

Whether air purification or filtration processes in production:<br />

the demand for new products and services remains high<br />

which is also demonstrated by the large number of exhibitors.<br />

At the moment the organizer is already expecting over 440<br />

companies at FILTECH 2023 – more than ever before.<br />

22 no. 4, November <strong>2022</strong>

news & facts<br />

Personal exchange at the heart of the congress<br />

Traditionally the FILTECH exhibition area is also complemented<br />

by a strong congress. Visitors thus not only<br />

have the opportunity to experience current products and<br />

services live but are informed about trends in research and<br />

development in the congress area. The FILTECH scientific<br />

advisory board, chaired by Dr. Harald Anlauf (KIT) and Prof.<br />

Eberhard Schmidt (Bergische Universität Wuppertal), guarantees<br />

the high quality of the presentations: experts from<br />

international universities, research institutions and companies<br />

review the submitted contribution proposals and compile<br />

a program that guarantees valuable information from all<br />

areas of the industry. The organizer expects more than 200<br />

presentations for FILTECH 2023. The congress at the event is<br />

divided into units covering all relevant topics.<br />

Seven thematic areas will be in focus:<br />

➢ solid-liquid separation<br />

➢ solid-gas separation<br />

➢ filter media<br />

➢ testing, instrumentation and control<br />

➢ simulation and modeling<br />

➢ product related processes<br />

➢ membrane processes<br />

In addition, the congress at FILTECH 2023 will be dedicated<br />

to current industry trends such as selective separation, micro<br />

process technology, and nanofluidics, mist and droplet separation<br />

as well as biological exhaust gas cleaning with biofilters.<br />

On February 13, 2023, already one day before the opening<br />

of the exhibition area, two focused one-day courses will<br />

be held, which will also specifically address engineers, scientists,<br />

managers, and other technical personnel who are interested<br />

in knowledge on topics related to solid-liquid separation<br />

and fine particle separation.<br />

Filtration processes for quality and reliability<br />

High dust levels, explosive dusts and pollutants endanger<br />

people, the environment and the plant. Filter solutions<br />

specifically designed for the harsh environments of processing<br />

prevent hazards to operators and the environment, increasing<br />

service life of the plant and equipment, ensuring<br />

high performance.<br />

At FILTECH processing companies will find the right<br />

products and services for this purpose and can exchange<br />

information with experts on current trends. For successful<br />

planning of the visit, interested parties can find a list of<br />

exhibitors, an overview of focus topics and industries as well<br />

as the extensive conference program at filtech.de.<br />

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

Topics for the future bear first fruits<br />

In light of the current global economic and political<br />

developments and challenges that come with them,<br />

MAPAL is working hard on future developments.<br />

MAPAL’s traditional main market, the automotive industry,<br />

remains a key pillar of its market strategy. With the addition<br />

of the future field of electric mobility, MAPAL solutions<br />

will be found in all areas of mobility. This also includes tool<br />

solutions for internal combustion engines until they are permanently<br />

discontinued. “Of course we also want to considerably<br />

strengthen our position in sub-segments other than<br />

power trains, for example with chassis and brakes,” explains<br />

Dr Jochen Kress, president of the MAPAL Group. The market<br />

segments of aerospace, fluid power technology and the die &<br />

mould sector are also in focus. MAPAL has gained a strong<br />

foothold in fluid power technology with intelligent solutions.<br />

The market strategy for the die & mould sector has now been<br />

rolled out worldwide. The necessary stock availability of tools<br />

is in place and structures are set up accordingly. Dr Kress<br />

explains: “We’re looking forward to the future with great<br />

optimism.” Across all segments, the machining of titanium<br />

and aluminium plays an important role in the market and<br />

product portfolio.<br />

The development and sales strategy aimed resolutely at the<br />

focus markets already began to bear fruit in the 2021 financial<br />

year: Group turnover rose to € 524 million, an increase of<br />

15 %. For the current year <strong>2022</strong> ongoing developments make<br />

it very difficult to make a reliable forecast. “The fact that our<br />

future developments are beginning to bear fruit is cause for<br />

optimism. The first six months of <strong>2022</strong> went well and according<br />

to plan.”<br />

The production area of the Altenstadt site was doubled<br />

thanks to the latest expansion<br />

Senior management is also looking beyond the current<br />

situation and investing in several sites worldwide. For example,<br />

completion of the construction work at the Altenstadt site<br />

means an increase in production space at the Center of Competence<br />

for solid carbide tools of 5,000 m 2 , improving the<br />

company’s ability to react in the competitive market significantly.<br />

Also in Poland substantial investments are being<br />

made. In India the construction project has been completed.<br />

Here a brand-new production and administration building<br />

was built, meeting the latest ecological standards.<br />

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

no. 4, November <strong>2022</strong><br />


news & facts<br />

fairs<br />

Manufacturing community reconnected at IMTS <strong>2022</strong><br />

With handshakes, hugs, high-fives and hearty backslaps,<br />

as people greeted each other after four years, the<br />

connectedness of the manufacturing community was<br />

the literal showstopper at IMTS – The International<br />

Manufacturing Technology Show.<br />

Held September 12-17 at Chicago’s McCormick Place, IMTS<br />

<strong>2022</strong> achieved a total registration of 86,307, including 11,715<br />

students and featured 1,212,806 million ft 2 of exhibit space<br />

representing 1,816 exhibitors and 1,603 booths. The North<br />

American visitor-to-exhibitor ratio increased by more than<br />

10 % compared to 2018’s record-breaking show, reaffirming<br />

the need to meet in person.<br />

“While the excitement and electricity were clearly evident<br />

in every aisle of the show, what was most gratifying for the<br />

industry and the country was the scope of commerce taking<br />

place as visitors sought out, and found, key technologies and<br />

productivity solutions to move their businesses forward,” says<br />

Douglas K. Woods, president of AMT – The Association For<br />

Manufacturing Technology, which owns and produces IMTS.<br />

“The digital technologies and other new products at this<br />

show aren’t just advanced: they are accessible, inclusive, and<br />

ready to be implemented by small and medium-sized businesses<br />

regardless of their workforce composition”, adds Peter<br />

R. Eelman, chief experience officer at AMT.<br />

“With the number of innovative products hitting the<br />

market now – cutting across the entire swath of automation<br />

and digital technologies that change the way we manufacture<br />

parts – we’re in a period of time that will not be paralleled<br />

again for decades” notes David Burns, principal and founder<br />

at Global Business Advisory Services. Burns points out that<br />

manufacturing technology orders per sale continued to increase<br />

from 2019 through <strong>2022</strong> and that they will continue to<br />

accelerate as companies use technology to compensate for a<br />

smaller labor force.<br />

The AM4U Area, presented by Formnext, a new venue<br />

for IMTS, featured well-attended daily presentations such<br />

as a panel of nine additive manufacturing experts discussing<br />

the benefits and drawbacks of various AM technologies.<br />

Formnext is the leading industry expo platform for additive<br />

manufacturing and industrial 3D printing.<br />

AMT and Gardner Business Media have collaborated with<br />

Mesago, the organizers of Formnext, and Messe Frankfurt<br />

Inc. to launch Formnext forum Austin (Aug. 28-30, 2023),<br />

the Formnext forum co-located at IMTS 2024, and Formnext<br />

Chicago (April 8-10, 2025) at McCormick Place.<br />

Automation<br />

After the human connection, IMTS <strong>2022</strong> will be remembered<br />

as the show of a thousand robots. Exhibitors integrated<br />

robots, cobots, and other automated functions to machining<br />

centers, welding systems, tooling centers, workholding pallets,<br />

inspection systems, and more.<br />

“The automation systems at IMTS focused on ease-of-deployment,<br />

iPhone-level programming simplicity, and affordability<br />

for small and medium-sized businesses,” says Tim<br />

Shinbara, chief technology officer at AMT. “Visitors could<br />

find new startup automation companies and spinoffs in every<br />

hall, and every one of them introduced solutions for highmix,<br />

low-volume applications to help job shops address their<br />

workforce and productivity issues.”<br />

Automation solutions at IMTS <strong>2022</strong> also combined the<br />

flexibility of a collaborative robot (cobot) with an autonomous<br />

vehicle that can drive around a shop and tend multiple<br />

machines without human intervention. Two exhibitors had<br />

eye-catching demonstrations of this technology. Staubli<br />

Robotics introduced the new HelMo mobile robot system,<br />

equipped with multi couplings, a tool-changing system, and a<br />

tool station. Nachi Robotic Systems demonstrated a CZ10 cobot<br />

arm mounted on an EffiBOT autonomous mobile robot<br />

simulating machine tending work.<br />

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

24 no. 4, November <strong>2022</strong>

news & facts<br />

Ambitious sustainability strategy<br />

“CO 2<br />

neutral” by 2025, “net zero” by 2040<br />

CERATIZIT presented an ambitious sustainability<br />

strategy on the occasion of AMB <strong>2022</strong> in Stuttgart.<br />

With the help of this strategy the company aims to<br />

become the leader in sustainability for the hard metal<br />

and cutting tool industry by 2025.<br />

Executive Board Member Thierry Wolter announced the<br />

ambitious sustainability goals, which will affect and change<br />

the entire supply chain, at AMB in Stuttgart. “Climate change<br />

is one of the greatest challenges of our time and requires the<br />

industry to rethink in many areas as well,” said Wolter. For<br />

CERATIZIT customers to also be able to produce more sustainably,<br />

the company has set itself ambitious targets for its<br />

own products and services. “Our vision is to be the leader<br />

in sustainability in the hard metal and cutting tool industry<br />

by 2025,” Wolter continues.<br />

Sustainability along the entire value chain<br />

In order to become sustainable throughout the company,<br />

CERATIZIT will look in future at the entire value chain with<br />

regard to environmental, social and governance criteria, ESG<br />

for short, and also include its cooperation with partners. In<br />

the first phase the focus will be on those aspects that have the<br />

greatest leverage effect.<br />

Reduction of the carbon footprint<br />

In order to drastically reduce its own carbon footprint quickly,<br />

CERATIZIT is initially focusing on three major levers. A<br />

decisive factor is the increase in the use of secondary raw<br />

materials to over 95 %. Compared to primary raw materials<br />

from ore, their processing requires 70 % less energy and<br />

reduces CO 2<br />

emissions by 40 %. A positive side effect is the<br />

safeguarding of the supply chain for raw materials, so that<br />

both the customers and CERATIZIT benefit twice.<br />

Another focus is on the power supply. CERATIZIT plans to<br />

switch the power supply of all sites to green electricity from<br />

wind, solar and water power in the next few years.<br />

Closely related to the change in power supply is the issue<br />

of hydrogen supply. It is needed as a production medium in<br />

the hard metal industry, especially for the production of tungsten<br />

powder. Up to now this hydrogen has mainly been obtained<br />

from natural gas by steam reforming, so-called “grey”<br />

hydrogen. For the future CERATIZIT plans to use “blue” hydrogen,<br />

which is produced from water by electrolysis with<br />

green electricity. For this purpose, CERATIZIT will cooperate<br />

with its existing suppliers and also build its own electrolysis<br />

plants.<br />

First milestone: CO 2<br />

neutral by 2025<br />

The first milestone in the implementation of the new<br />

strategy is 2025, by which time CERATIZIT plans not only<br />

to be CO 2<br />

neutral, i.e. to offset all emissions along the entire<br />

supply chain. The goal is also to reduce the actual emissions<br />

by 35 % compared to the reference year 2020. The<br />

second stage, 2030, envisages a reduction of 60 % compared<br />

to 2020 with the help of further measures.<br />

The most ambitious goal, however, is to achieve “net zero”<br />

by 2040 – a target envisaged by the Paris Climate Agreement<br />

only for 2050. “Reducing CO 2<br />

emissions along the entire<br />

value chain by at least 75 % by 2040 is without question a<br />

challenge. However, with a view to future generations we<br />

see no alternative to this path and are pleased to also let our<br />

customers participate in this through products such as our<br />

“GreenCarbide” rods, our award-winning SilverLine milling<br />

cutter with sustainability formula as well as a wide range of<br />

services,” Wolter explains the company’s motivation.<br />

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

no. 4, November <strong>2022</strong><br />


news & facts<br />

LACH DIAMANT – 100 Years<br />

Tradition. Passion. Innovation<br />

part 3:<br />

From natural diamonds to synthetic diamonds<br />

“When I held my first diamond in my hand in 1908, I<br />

would not have imagined that one day diamonds would<br />

not only be used in the automobile industry but also<br />

for the machining of wood and plastics”. Jakob Lach,<br />

the company founder, said this on camera in 1980.<br />

It would become the preface for the first presentation<br />

of a new technique for machining wood and plastics<br />

– using diamonds as cutting material – the Dia<br />

Tool. This video, with audio translated into multiple<br />

languages, has lost none of its relevance for the choice<br />

of appropriate tools within the furniture, flooring and<br />

plastic industries, the video can be viewed at:<br />

https://bit.ly/LACHDIAMANT<br />

1957 was not only the year of the first signalling satellite<br />

“Sputnik” orbiting the earth. It was also the year which<br />

would propel the company LACH DIAMANT, Jakob Lach<br />

GmbH & Co. KG, to new heights – something no one at<br />

LACH could have foreseen at the time. The reason being that,<br />

in 1957, an American manufacturer named General Electric<br />

was the first to offer synthetically produced diamonds, socalled<br />

man-made diamonds, to the industry. More precisely,<br />

it was a developer of super abrasive materials, which would<br />

later set up shop in Worthington, Ohio, under the umbrella<br />

of GE Light Bulbs. From today’s perspective this could be defined<br />

as a mile stone for the beginning of the “diamond age”<br />

in our modern industry. For the first customers or users of<br />

this material, synthetic diamond grains, it was “only” an opportunity<br />

to switch from one natural material to a synthetic<br />

alternative. The application was predominantly as polishing<br />

Company founder Jakob Lach, 1894-1984<br />

(photo taken in 1980)<br />

and lapping grain, used in metal-bond bronze grinding<br />

wheels and in resin (rubber)-bond grinding wheels which<br />

were still in development at the time. The first synthetic<br />

diamonds could influence the development of carbide or<br />

carbide tools only insignificantly. The reason being that these<br />

grains lacked the ability to anchor themselves to the resin<br />

bond in order to provide the necessary chip spaces for pregrinding.<br />

This requirement would only be solved ten years<br />

later by ASEA, Friedberg, in Hessen, through the develop -<br />

ment of a procedure for the metal-coating of synthetic diamond<br />

grains.<br />

With this coating the plastic binder could now tightly<br />

attach to the metal-coated diamond. The diamond was now<br />

usable for up to 85 % until breaking out of the binder, even<br />

when pre-grinding carbides. More about that later.<br />

Diamonds as tools<br />

When I, Horst Lach, started in my father’s company on<br />

October 1 st , 1960, after completing my education as an industrial<br />

management assistant, I was “learning by doing” how<br />

diamonds could be used as tools. At that time there was absolutely<br />

no literature available on the use of diamond tools,<br />

with the exception of an occasional company brochure or<br />

some war-time research on the manufacturing of sintered<br />

multi-grain diamond dressing tools, so that even the smallest<br />

remnants of used single-grain diamonds could still be used<br />

for dressing grinding wheels.<br />

At universities and at other educational facilities the topic<br />

of “Using Diamonds for Efficient Production” was, if at all,<br />

underrepresented; this would change only within the last 25<br />

years.<br />

Even today, this information board on the correct handling of<br />

single point diamond dressers should be displayed<br />

in every training workshop.<br />

In the 1950’s, Jakob Lach had already established the basis<br />

for the enterprise I found in 1960: industrial diamonds were<br />

used for dressing grinding wheels in the ball bearing, anti-<br />

26 no. 4, November <strong>2022</strong>

news & facts<br />

Jakob Lach congratulates Kurt Wagner, manager of the diamond<br />

cutting shop, on his birthday; right side Willi Reusswig (photo taken<br />

around 1965 in the Hanau facility at Bruchköbeler Landstrasse)<br />

A view into a natural diamond cutting shop, servicing single<br />

dressing diamonds and profile diamonds as well as<br />

natural diamonds (photo taken around 1967)<br />

friction bearing, electrical and the mechanical engineering<br />

industries as well as by crankshaft cylinder grinding shops.<br />

Contrary to today, back then customers were presented with<br />

a selection of loose diamonds (raw diamonds) from larger<br />

batches, and they could select the diamonds based on their<br />

own personal preferences. The customers themselves would<br />

then set the diamonds in holders. Fortunately for us, there<br />

was one exception among the high-volume customers, drive<br />

shaft manufacturer Lohr & Bromkamp GmbH in Offenbach,<br />

today known as GKN. For this particular company we kept<br />

a permanent on-call stock of set diamonds for morse tapers<br />

0 and 1, in top-notch quality between 1.5 and 2.3 ct, with a<br />

monthly order rate of 10 to 20 pieces. Profile cut diamonds,<br />

2-2.5 ct for MSO machines, would soon be added.<br />

Early marketing<br />

Decades of a good cooperation with this customer proved to<br />

be a model case for the positive future development of LACH<br />

DIAMANT as it was now called. During my apprenticeship<br />

at the end of the 1950’s, after I was confronted with the concept<br />

and basics of “marketing” by my boss, and after I was<br />

entrusted with “introducing marketing” in two facilities, it<br />

also had a high priority for me at LACH DIAMANT. It might<br />

be interesting to some of the readers, which marketing tools<br />

were available in those days.<br />

– for the acquisition of potential customers:<br />

various address books, ranging from the “ABC of<br />

German economy” to telephone or later telex directories<br />

– for the evaluation of potential customers:<br />

sales estimates/account cards from our own accounting<br />

department/credit agencies<br />

– initial contact was made via:<br />

telephone, telex, postal mail, advertisements,<br />

personal visits<br />

In other words very tedious and time-consuming work.<br />

Potential market companions with a conventional “diamond<br />

background” (diamond cutting shop or diamond retailer)<br />

were noted in our “marketing file”, such as Winter & Son in<br />

Hamburg, Urbanek in Frankfurt and Dürr in Cologne. A new<br />

company logo was designed, showing a symbolized holder<br />

with a set octahedron diamond in an inclined dressing position<br />

(as seen on the information board which was used until<br />

the year 2000).<br />

Demand for new services<br />

A growing demand from the cutting shops for more and<br />

more consistent precision required the use of single point<br />

dressing diamonds and thus also created the wish for a fast<br />

repair service. Depending on the quality, set octahedron<br />

diamonds show up to six suitable tips for dressing; when they<br />

are no longer usable for the desired results, the diamond has<br />

to be removed from its holder or be reset to the next useable<br />

Synthetic man-made diamond grains for resin-bond diamond<br />

grinding wheels – left with metal coating – right without<br />

metal coating (state of development from around 1968).<br />

no. 4, November <strong>2022</strong><br />


news & facts<br />

Doctor Fritsch, owner of the company with the same name,<br />

personally operates the first diamond grinding wheel press –<br />

a press sintering machine<br />

(photo taken around 1963)<br />

tip. When all tips are worn, a diamond cutter can resharpen<br />

the natural diamond and create a new tip. This was the result<br />

of a first study on the topic “Fast service for repairing single<br />

diamonds”.<br />

The “Express LACH Repair Service” was born – re-setting<br />

within 24 hours. The first marketing success, and executed<br />

accordingly, except for the fact that, due to our own production<br />

capacity limitations, this work was first carried out by<br />

a partner company until it became too much for them. Any<br />

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

service internally again. It was the start for our own diamond<br />

tool production.<br />

Diamond tools, made at LACH<br />

Diamond cutters were employed again, among them experienced<br />

cutters like Kurt Wagner and Willi Reusswig; both had<br />

received excellent training at a well-known manufacturer of<br />

turning diamonds for the watch- and clock-making industry<br />

in Switzerland. Gradually the necessary machines were<br />

purchased. Among them the first press sintering machine<br />

for the production of metal-bond diamond grinding wheels<br />

and multi-grain dressers, personally put into operation by the<br />

developer Dr. Fritsch in 1962/63.<br />

Thanks to Kurt Wagner’s know-how as manager of the diamond<br />

cutting shop with approximately 20 workers, they succeeded<br />

in winning Bosch-Bühlertal as customer for the production<br />

and service of the necessary turning diamonds for<br />

overturning the copper commutators produced there. Word<br />

got around. From then on even commutator manufacturers<br />

such as AEG and Siemens were among our customers. The<br />

young production team grew day by day, proud of the problems<br />

solved.<br />

At the beginning of the 1960’s my father and I began to take<br />

turns in presenting raw products to customers; if I remember<br />

correctly, we were travelling at times with materials insured<br />

up to 1 million DM. Jakob Lach was still personally in charge<br />

At Hanover trade show in 1968, and to an astonished audience<br />

of experts, Karl Ruth demonstrates cutting with a newlydeveloped<br />

resin-bond diamond grinding wheel (K-MC bond)<br />

with a metal-coated diamond grain on a<br />

Simon steel grinding machine<br />

of purchasing the diamonds in Antwerp/Belgium. At the<br />

beginning of the 1960’s, an external employee assisted with<br />

sales. Otto Lang had started as an independent sales represenative<br />

around the same time as I had. He travelled weekly<br />

from his residence in Schorndorf to Baden-Württemberg.<br />

He left at 6 am on Mondays, returning on Fridays with a<br />

full order book. On Saturdays his wife completed the results<br />

of his long trips with visit reports and mailed them at<br />

the post office. On Sundays between 11 and 12 am, we took<br />

turns picking up the already sorted Saturday mail from our<br />

lock box at the main post office in Hanau. And of course<br />

father and son took a first look at the visit reports and orders.<br />

In case of orders for single dressing diamonds, my father<br />

did not let himself be deterred from immediately starting to<br />

process the order by selecting suitable “stones” and preparing<br />

the order for fulfillment on the following Monday. The Lang<br />

couple became good friends of our family, especially since<br />

they later became the godparents for my son Robert.<br />

In the 1960’s, sales representatives were also added in Bavaria<br />

(Nuremberg) and North Rhine-Westphalia (Düsseldorf), in<br />

addition to Baden-Württemberg.<br />

Increased monthly sales<br />

Monthly sales increased. In the beginning, I had kept track<br />

of the rising curve on graph paper. However, after I had to<br />

attach three to four new sheets for extending the curve, I<br />

surrendered and observed future trends solely based on the<br />

account sheets of the accounting department.<br />

During the early 1960’s you did not have to analyse the<br />

numbers in detail to see that turnover originated mainly<br />

from sales of industrial diamonds or dressing tools respectively.<br />

However, due to increased activities of our sales representatives,<br />

we now also received delivery inquiries for diamond<br />

grinding wheels for glass (lead crystal) and carbide<br />

machining. Our previously mentioned market companions in<br />

Hamburg and Frankfurt offered us a resale discount of 10 %<br />

on inquiries for diamond grinding wheels – not enough for<br />

28 no. 4, November <strong>2022</strong>

news & facts<br />

received my first hints and tips from a lab manager at<br />

Bakelite company. But as an industrial business management<br />

assistant I must have confused some of the instructional<br />

details. He talked about aluminium oxide as a filling<br />

agent, and I thought it was aluminium powder. When the somanu<br />

factured test wheels came into operation on a Finimat<br />

carbide tool sharpening machines, developed by engineer<br />

Erwin Vollmer in Dornhan, people were very enthused about<br />

the number of teeth registered by an automated counter;<br />

the coating, “shining with power”, hardly showed any wear.<br />

Even years later, sales representatives did not quite know how<br />

to deal with frequently incoming reorders.<br />

A view into part of the diamond wheel production<br />

in the mid-sixties: Ute Kiesel and Karl Ruth in the process<br />

of filling wheel forms<br />

Then, finally – 1966/67 – the previously repeatedly mentioned<br />

metal coating for synthetic diamonds became reality<br />

in the form of the de Beers Kornes RDA-MC (MC standing<br />

for metal coating). Developed by the company ASEA, bought<br />

out and patented by de Beers. This meant for General Electric<br />

that they had to pay a license fee of 5 cents to de Beers for<br />

every sold carat of the diamond grain with metal coating.<br />

business operations and commissions for our sales representatives.<br />

After installing a pressure sintering machine, we had<br />

fewer problems with metal-bond grinding wheels; we could<br />

do our own calculations based on the required diamond<br />

content.<br />

In those years, the wheels which we already manufactured<br />

in-house, were mostly sold to manufacturers of lead crystal,<br />

such as the company Nachtmann, Peil and Putzler which had<br />

invested in new grinding machines, e.g. Kutscher machines.<br />

Attempts to enter the market for eyewear failed due to prevailing<br />

price demands.<br />

After making the first wheel for ceramics for Feldmühle,<br />

Plochingen (with dimensions of 400 x 200 mm width and<br />

one (!) mm layer depth) and resulting, to the great dismay of<br />

Dr. Fritsch, in the transformer of the sintering machine<br />

going up in flames, we left this particular market segment for<br />

the time being.<br />

Resin-bond diamond grinding wheels<br />

Our lack of a competitive edge and the general topic of resinbond<br />

diamond grinding wheels remained a topic of great interest<br />

to us. Attempts to procure such wheels from newly<br />

emerged manufacturers in France and the Netherlands were<br />

not that successful. Reasons for failure were the lengthy and<br />

tedious communication (via telex), as well as delivery times<br />

and, most annoying to us, the lack of consensus on determining<br />

the respective diamond content of each wheel. The latter<br />

was even in the 1960’s a significant factor for comparing<br />

prices and bids. The exact diamond content had to be noted<br />

depending on the concentration (for example, concentration<br />

in percent by volume C = 100 = 4.4 ct per cm 3 ).<br />

What to do? Manufacture in-house? But where would the<br />

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

literature was scarce on the subject, even the first usable<br />

plastics were sold as “secret recipes”. Not to mention<br />

mixing proportions for filling agents or compounds. I<br />

During the boom of the 60’s:<br />

metal-bond diamond grinding wheels for automated cutting<br />

of crystal glasses on Kutscher machines.<br />

no. 4, November <strong>2022</strong><br />


news & facts<br />

I claim that this idea of coating synthetic<br />

diamond grains with a spattered<br />

metal coating (which allows for<br />

the resin to tightly latch onto its “coral-like”<br />

surface), was solely responsible<br />

for the boom-like success of<br />

carbide in the tool industry, and of<br />

course for the success of the resinbond<br />

diamond grinding wheel. Finally,<br />

the prevailing school of thought<br />

that diamond grinding wheels could<br />

only be used for lappers and polishers<br />

of carbide, could be successfully<br />

refuted. The now available metalcoated<br />

diamond grains allowed for<br />

pre-grind ing and even deep grinding<br />

operations with resin-bond<br />

wheels. Especially manufacturers of<br />

wood machining tools, such as Ledermann,<br />

Leitz and Guhdo, as well as<br />

the machine manufacturers for these<br />

tools, such as the companies Vollmer<br />

in Dornhan and Biberach, and for<br />

example Stehle and Kuhlmann,<br />

would profit the most in this period<br />

of prosperity. To name a few representatives for metal tool<br />

manufacturers, the companies Walter, Carboloy/USA and<br />

Sandvik/Sweden can be listed. Among the many precision<br />

machine manufacturers that now distinguished themselves<br />

on the market, Jung (flat grinding machines) and PTW (optical<br />

profile grinding machines) remain as outstanding companies<br />

in my memory.<br />

Ad hoc, the metal-coated diamond would influence the<br />

further development of LACH DIAMANT as well. “MC”<br />

(metal-coated diamond) was added to the “K” (Kunststoff –<br />

the German word for plastic), as K-MC (representing resinbond<br />

LACH DIAMANT grinding wheels with metalcoated<br />

synthetic diamond grains). With the new K-MC<br />

LACH DIAMANT first time at Hanover trade show 1967, being co-exhibitor from<br />

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

Otto Lang and as special guest figure skater Matzdorf<br />

grinding wheel we were able to win the company Simon in<br />

Neu-Isenburg as our biggest new customer as their machine<br />

supplier for the double-tool-grinding machine L15 for lapping<br />

and tension grinding of soldered carbide steels; at that<br />

time we already supplied the also needed metal-bond flute<br />

grinding wheels. In the meantime a lot of other developments<br />

had happened at LACH DIAMANT. We had indeed<br />

succeeded in gaining much-sought after admission to the<br />

spring trade show in Hanover. We were co-exhibitors with<br />

Hoffmann & Co, Maulbronn. When they were looking for<br />

a mechanic to demonstrate the use of a deburring tool for<br />

auto bodies we stepped in. In return they allowed us to give a<br />

demonstration with the new K-MC diamond grinding wheels<br />

on the previously mentioned Simon steel grinding machine.<br />

Bad luck for our endeavour to show off a new deburring tool.<br />

Unfortunately the demonstration of the “deburring process”<br />

on the sheet metal auto body proved to be so annoyingly loud<br />

that all exhibitors from hall 7 voted unanimously to stop<br />

this presentation at that time. However, it was a trade show<br />

debut for LACH DIAMANT. At the very next trade show<br />

we already had our own stand. By the way, at approximately<br />

the same time LACH DIAMANT became a member of FWI,<br />

the professional association of the tool industry, section<br />

diamond tools.<br />

LACH DIAMANT at Hanover trade show, spring 1968, for the<br />

first time with our own booth; featured diamond tools were<br />

dressing tools, natural turning diamonds, resin- and metalbond<br />

diamond grinding wheels, diamond pastes and the spray<br />

MF programme; in the center Kurt Wagner (left) in<br />

conversation with Jakob Lach.<br />

My father, being then almost 75 years, who also noticed<br />

the positive development of our company, then gave the goahead<br />

for major extensions of the natural diamond cutting<br />

shop which later became the location of the diamond wheel<br />

production facility and sintering technology.<br />

A good and wise decision, as you, my dear readers, will be<br />

able to confirm after the next report that begins with the year<br />

of 1969.<br />

Your Horst Lach<br />

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

30 no. 4, November <strong>2022</strong>

news & facts<br />

Four generations and 100 years in metal cutting<br />

Preben’s grandfather,<br />

Louis Eckart Hansen<br />

In a world where<br />

machine shops are<br />

struggling to stay<br />

open and maintain<br />

their business<br />

and “going into<br />

dad’s business” is<br />

not what it once was,<br />

Platinum Tooling<br />

is an exception to<br />

the rule. Located in<br />

Prospect Heights,<br />

Illinois, the company<br />

is set to reach an important<br />

milestone. In<br />

<strong>2022</strong>, company president<br />

Preben Hansen<br />

and his family will<br />

celebrate 100 years<br />

working in metal cutting<br />

and four generations<br />

of Hansen men<br />

in the industry. How<br />

cool is that?<br />

The story began with Preben’s grandfather, Louis Eckart Hansen,<br />

who learned his trade in Copenhagen, Denmark in the<br />

early 1900’s. Louis worked as a machinist in the Danish Navy’s<br />

repair facility. Preben’s father, Svend Eckart Hansen,<br />

honed his skills under the guidance of Louis. 1958 Svend emi -<br />

grated to the U.S.A., with his family including young Preben.<br />

Despite not knowing English, he found employment within<br />

days of arriving in Chicago, because of his skill as a tool<br />

maker. Svend began his career as a machinist and ended it<br />

in the 1990’s as a master tool maker at Ramcel Precision<br />

Stamping and Manufacturing LLC in Northbrook, Illinois.<br />

With manufacturing and tooling in his DNA, Preben<br />

worked in the machine shop of the former Fulton Machine<br />

Company in downtown Chicago, while attending the University<br />

of Illinois/Chicago and pursuing a degree in engineering.<br />

After college he worked in the shop at Oakley Industries<br />

building custom machinery. After several years there Preben<br />

moved to the front office and to an inside sales position.<br />

Preben with his dad, Svend Eckart Hansen<br />

Later, at Jemco Tool & Die, he learned programming and setup<br />

on their CNC lathes and machining centers which was his<br />

introduction to machine tools and their accessories. His next<br />

job was at HPI, now known as Pioneer Heartech Precision<br />

Inc., a distributor of tool holders and related products, in<br />

Elk Grove Village, Illinois. Preben started as an outside sales<br />

repre sentative of tool holders and rotary tables, then became<br />

the company’s sales manager. This was followed by<br />

Lyndex-Nikken, another machine tool accessory supplier in<br />

Mundelein, Illinois. Preben was introduced to live tools and<br />

once again worked as sales manager. In 2010, Preben started<br />

a joint venture with heimatec GmbH, becoming the president<br />

of Heimatec, Inc., a company specializing in live tools,<br />

angle heads and multispindle drill heads. 2018 Heimatec, Inc.<br />

was purchased by Platinum Tooling Technologies, Inc. with<br />

headquarters located in Prospect Heights, Illinois. Preben<br />

Hansen is the COO and president at Platinum Tooling.<br />

Preben has over 30 years of experience in the machine tool<br />

accessory market and over 40 years in the manufacturing industry.<br />

Given his credentials, it’s no surprise that Preben has<br />

established himself as a leading authority on these topics in<br />

the North American machine tool accessory market. He often<br />

hosts knowledge bars at trade shows to SRO crowds.<br />

Preben Eckart Hansen and his son Luke James Hansen<br />

In keeping the family tradition, Preben’s son, Luke Hansen,<br />

joined his dad’s company in 2018 as a technical sales specialist<br />

for several of the product lines sold by Platinum Tooling,<br />

including Tecnicrafts collets and guide bushings for Swiss<br />

machines. After graduating from high school Luke joined the<br />

army and received great training there. Upon his discharge,<br />

he used the motivational and goal orientation skills he had<br />

learned in the army. In his current position at Platinum<br />

Tooling Luke continues to expand his knowledge of the<br />

machine tool accessory market as well as builds valuable<br />

relationships with the North American sales and distribution<br />

network of the company.<br />

Reflecting on 100 years as a family in the manufacturing<br />

industry, Preben Hansen says, “The machine tool industry<br />

has been and continues to be an extremely vital part of our<br />

country’s continued success. My son Luke and I are proud<br />

to be 3 rd and 4 th generation professionals involved in this<br />

exciting industry.”<br />

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

no. 4, November <strong>2022</strong><br />


processes<br />

Retrofit unit for cryogenic process cooling<br />

written by<br />

Thomas Götz and Andreas Gebhardt,<br />

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

The use of carbon dioxide as a cooling medium can<br />

significantly improve the economic efficiency of machining.<br />

For the simple retrofitting of cryogenic cooling<br />

technology in existing machines, MHT GmbH Merz &<br />

Haag and Fraunhofer IPA have developed and successfully<br />

tested a new solution.<br />

In the machining process, tool and workpiece are subjected<br />

to high mechanical loads, whereby the mechanical energy applied<br />

for chip formation is almost entirely converted into heat<br />

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

the resulting heat flows are dissi pated with the chip, while the<br />

remaining approx. 25 % are introduced into the cutting tool<br />

or the workpiece. On the one hand, this thermal load leads to<br />

an intense heating of the workpieces, which is associated with<br />

a corresponding expansion of the latter. In addition, the high<br />

temperatures cause signs of wear on the cutting tool, such as<br />

mechanical abrasion, diffusion processes or scaling. These<br />

effects have a negative impact on the machining quality<br />

and machining accu racy of the workpieces as well as the tool<br />

life. (Klocke und König 2008; Lang 2012)<br />

Cooling strategies in machining technology<br />

Cooling lubricants are typically used to avoid or reduce a<br />

temperature load in the machining process whereby cutting<br />

tools and workpiece are usually flooded with the cooling<br />

lubricants. This cooling strategy, known as wet machining,<br />

does not only allow the removal of the process heat from the<br />

tool-workpiece contact point by cooling, but also a reduction<br />

of frictional heat by lubrication. Cooling lubricants thus<br />

contribute to a high level of performance in a wide range of<br />

machining processes. (Lang 2012)<br />

Alongside the technological advantages associated with<br />

the use of cooling lubricants, however, they pose a not insignificant<br />

risk to people and the environment. For example,<br />

cooling lubricant components such as bactericides and fungicides<br />

can trigger illnesses in the event of contact or aspiration.<br />

In addition, leakage and drag-out losses, washing<br />

water or the disposal of used cooling lubricants lead to pollution<br />

of soil, water and air. Legislators have therefore imposed<br />

strict regulations on the handling and disposal of cooling<br />

lubricants. For the industry, these requirements involve,<br />

apart from a high level of responsibility towards their employees,<br />

a high financial burden as well (e.g. disposal costs).<br />

(Klocke und König 2008; Koch 2015)<br />

One approach to completely avoid the use of cooling lubricants<br />

is the so-called dry machining, in which either limited<br />

air cooling is realized or completely without cooling. In dry<br />

machining, the coatings of the used cutting tools are therefore<br />

of particular importance, with the aid of which the thermal<br />

load on the cutting materials is to be reduced and adhesion<br />

and friction processes between the cutting tool and the workpiece<br />

are to be reduced, too. Disadvantages of dry machining<br />

include, among others, higher heat generation in the process,<br />

which can have a negative effect on dimensional accuracy,<br />

and the elimination of chip removal by cooling lubricants.<br />

If the lubricating effect of cooling lubricants cannot be completely<br />

dispensed with, minimum quantity lubrication can<br />

also be used during machining. With this cooling method,<br />

an aerosol of air and lubricant is fed to the cutting point.<br />

(Lang 2012)<br />

figure 1:<br />

Energy conversion and heat during machining<br />

(Kühn et al. 2018)<br />

Another alternative to conventional cooling lubrication<br />

concepts is cryogenic process cooling (figure 2). Here, media<br />

with extremely low temperatures are used for cooling. Typical<br />

cryogenic media are liquefied gases such as hydrogen<br />

(boiling point 20.268 K = -252.882° C) and nitrogen (boiling<br />

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

point 194.5 K = -78.5°C). (Klocke 2017)<br />

32 no. 4, November <strong>2022</strong>

processes<br />

Major drawbacks of using hydrogen and<br />

nitrogen in machining are the complex<br />

storage, feeding and insulation technology.<br />

For example, liquid nitrogen boils under<br />

atmospheric pressure, which is why<br />

vacuum-insulated containers must be<br />

used for storage. (Klocke 2017; Awiszus et<br />

al. 2020)<br />

In comparison, carbon dioxide (CO 2<br />

) is<br />

much easier to handle as a cooling medium<br />

because CO 2<br />

is in liquid form at room temperature<br />

and under high pressures. This<br />

property allows the liquid CO 2<br />

to be fed<br />

through a pipeline to the machining site<br />

under a pressure of 6MPa without insulation.<br />

(Klocke 2017; Awiszus et al. 2020)<br />

At the time of discharge, an abrupt pressure<br />

drop affects the liquid CO 2<br />

, which<br />

subsequently expands to a mixture of<br />

solid (45 %) and gaseous (55 %) states. The<br />

solid phase of the mixture is also referred<br />

to as dry ice and has a significantly higher<br />

cooling capacity as compared to the gaseous<br />

phase. (Klocke 2017)<br />

The carbon dioxide does not form harmful<br />

vapors and mists that can be inhaled<br />

with the air, so there is no health risk for<br />

the operator. Also, the cleaning of the<br />

workpieces or the disposal of the chips is<br />

simple. The workpieces remain dry and are<br />

not contaminated with oils and greases,<br />

which means that a final cleaning of the<br />

workpieces is largely unnecessary.<br />

figure 2:<br />

Cooling lubrication processes in machining production<br />

(after Lang 2012)<br />

Systems currently available on the market for cryogenic internal cooling use<br />

the concept of feeding the cooling medium through the motor spindle by means<br />

of a rotary feedthrough. However, this concept is associated with an increased<br />

risk of unwanted cooling of machine components, which in turn can lead to<br />

inaccuracies in the production or greater wear. In addition, the required<br />

modification of the motor spindle is complex and cost-intensive. (Volz und<br />

Abele 2019)<br />

Feeding strategies of<br />

cryogenic cooling<br />

In the case of cryogenic feeding strategies,<br />

a fundamental distinction can be made<br />

between cryogenic flood cooling and cryogenic<br />

internal cooling (figure 3).<br />

In cryogenic flood cooling, the machining<br />

point is flooded with the cryogenic cooling<br />

medium from the outside. Although<br />

this feeding strategy is simple to implement,<br />

it is also associated with some disadvantages.<br />

On the one hand, the cooling<br />

medium does not reach the cutting edge of<br />

the tool sufficiently, and on the other hand,<br />

there is a high consumption of the cooling<br />

medium required. In comparison, cryogenic<br />

internal cooling achieves a significantly<br />

higher cooling capacity, since the<br />

cooling medium is fed directly to the machining<br />

point. In addition, the consumption<br />

of the cooling medium can be significantly<br />

reduced with this feeding strategy.<br />

(Lang 2012)<br />

figure 3:<br />

Feeding strategies of cryogenic cooling<br />

(Lang 2012)<br />

Retrofit unit for cryogenic cooling<br />

Due to the existing disadvantages of a coolant supply through the motor<br />

spindle, the use of the IKZ medium distributor of MHT GmbH for cryogenic<br />

machining using CO 2<br />

was investigated as part of a joint project between<br />

MHT GmbH Merz & Haag and the Fraunhofer Institute for Manufacturing<br />

Engineering and Automation IPA. The medium distributor is an independent<br />

system for internal cooling (IKZ), consisting of the components spindle attachment,<br />

IKM annular body and IKM tool holder (figure 4). The system is characterized<br />

by the fact that it can be retrofitted in existing machines at low cost and<br />

without great effort.<br />

no. 4, November <strong>2022</strong><br />


processes<br />

figure 4: IKM- medium distributor<br />

Within the project, liquid CO 2<br />

was supplied from immersion<br />

tube bottles using a high-pressure hose via the spindle<br />

attachment, whereby the feed could be controlled via a solenoid<br />

valve, which was interposed immediately in front of<br />

the spindle attachment.<br />

As soon as the solenoid valve was opened, the liquid CO 2<br />

got into the internally cooled cutting tool via the interfaces<br />

on the ring body and the tool holder and expanded to CO 2<br />

snow when exiting the cooling channel. Extensive research<br />

has shown that the MHT system, which is actually designed<br />

for MQL or compressed air, also seems suitable for cryo genic<br />

cooling.<br />

A control system was also developed<br />

for actuating the solenoid valve,<br />

in which the feed is carried out via<br />

freely definable machine parameters.<br />

The machine parameters are provided<br />

by the machine control used, a Siemens<br />

Sinumerik 840d CNC control, via an<br />

OPC UA server, queried with the aid of<br />

the Node-RED development tool and<br />

transmitted as a trigger signal to an industrially<br />

suited, freely programmable<br />

PLC of the CONTROLLINO type. The<br />

PLC uses the trigger signals to open<br />

or close the solenoid valve so that the<br />

liquid CO 2<br />

can be fed to the machining<br />

point through the cooling channel<br />

of the cutting tool. In the future,<br />

the control system will make it possible<br />

to implement a speed-, tool- or<br />

material-dependent coolant supply.<br />

Summary and outlook<br />

Within the scope of the joint project, a retrofit unit based<br />

on MHT medium distribution for cryogenic process cooling<br />

was developed and successfully tested. Further future<br />

research is needed to observe the effects of the CO 2<br />

cooling<br />

medium on the tightness at the interfaces over a longer<br />

period of time. In addition, further extensive tests on cryogenic<br />

machining should be carried out. Here, the focus<br />

should be primarily on the evaluation of tool life and surface<br />

quality under variation of cutting tools, materials, contact<br />

widths, speeds as well as the CO 2<br />

volume flow. The knowl -<br />

edge gained from this should be used to implement an intelligent<br />

control system.<br />

Literature<br />

Awiszus, Birgit; Bast, Jürgen; Hänel, Thomas;<br />

Kusch, Mario (eds.) (2020)<br />

Grundlagen der Fertigungstechnik<br />

Carl Hanser Verlag. 7. fully revised and expanded edition.<br />

München: Hanser (Hanser eLibrary)<br />

Klocke, Fritz (2017)<br />

Fertigungsverfahren 1.<br />

Zerspanung mit geometrisch bestimmter Schneide<br />

Berlin: Springer Vieweg (VDI-Buch)<br />

Klocke, Fritz; König, Wilfried (2008)<br />

Drehen, Fräsen, Bohren<br />

8. edition [newly edited].<br />

Berlin: Springer (VDI-Buch, volume 1)<br />

Koch, Thomas (2015)<br />

Mikrobiologie der Kühlschmierstoffe<br />

1. edition. Tübingen: expert verlag (series Technik).<br />

Available online: http:<br />

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

Kühn, Klaus-Dieter; Fritz, Alfred Herbert;<br />

Förster, Ralf; Hoffmeister, Hans-Werner (2018)<br />

Trennen<br />

In: Alfred Herbert Fritz (ed.): Fertigungstechnik.<br />

Berlin, Heidelberg: Springer Berlin Heidelberg<br />

(Springer-Lehrbuch), page 225 – 378<br />

Lang, Heiner (2012)<br />

Cryogenic – Zerspanen mit tiefkaltem Stickstoff<br />

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

Volz, Marcel; Abele, Eberhard (2019)<br />

Innovative Chuck with Integrated Rotary<br />

Feed-Through for Drilling Process with<br />

Application of Cryogenic Cooling<br />

In: Robert Schmitt und Günther Schuh (eds.):<br />

Advances in Production Research.<br />

Cham: Springer International Publishing, page 278 – 287<br />

further information: www.ipa.fraunhofer.de<br />

34 no. 4, November <strong>2022</strong>

processes<br />

New standards for eroding<br />

The sharpening specialist VOLLMER has boosted<br />

its VHybrid 260 grinding and erosion machine,<br />

and now achieves a surface quality of 0.05 μm/Ra<br />

(micrometre/average roughness value) when eroding<br />

PCD tools (polycrystalline diamond). The process<br />

innovation succeeded thanks to the optimisation of<br />

the Vpulse EDM Generator.<br />

The optional V@ boost solution is designed for drills or<br />

milling cutters of a Ø of 1.0 mm. Such small PCD tools are<br />

mainly used in sectors such as automotive construction,<br />

medical engineering or the electronics and aerospace sectors.<br />

These days, PCD cutting tools are an essential component<br />

for many modern industrial manufacturing procedures.<br />

Thanks to their hardness and wear resistance, they are ideal<br />

for machining light metals, fibre composites, brittle-hard<br />

materials, as well as wood/wood composites. However, sharpening<br />

PCD tools is increasingly challenging even for experienced<br />

manufacturers. Especially if tools have to be ground or<br />

polished on various functional areas following erosive machining.<br />

For this purpose an additional work step is usually<br />

downstreamed, bringing with it an exacting process design.<br />

Generator with adaptive control<br />

The Biberach-based sharpening specialist VOLLMER has<br />

now succeeded in significantly improving this eroding process<br />

using their VHybrid 260 grinding and erosion machine<br />

in one set-up. Thanks to the new performance package for the<br />

Vpulse EDM generator, it is possible – for the first time – to<br />

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

(micrometre/average roughness value) in unmanned loader<br />

operation when eroding using the VHybrid 260. These<br />

values can be achieved thanks to the use of adaptive control<br />

technology together with the familiar innovative yet robust<br />

kinematics of the VHybrid 260 in combination with minimal<br />

discharge energy levels. This means that the finest of surfaces<br />

can be achieved. The savings in cost-intensive follow-up processes<br />

created by this provide the manufacturers of PCD tools<br />

with a profitable business, since they reduce the manufactur-<br />

100,0 μm<br />

1000,0 μm<br />

The size comparison with a matchstick shows how precisely<br />

the Vollmer VHybrid 260 with the new V@ boost solution<br />

can sharpen ultra-thin carbide tools<br />

ing costs per tool and increase the quality and durability for<br />

the end user. For the future it will also be possible to manufacture<br />

full-head PCD tools costefficiently in the smallest<br />

diameter ranges.<br />

The VHybrid 260 joined the party at AMB<br />

At AMB <strong>2022</strong>, the metalworking trade show in Stuttgart,<br />

interested parties at the VOLLMER stand could watch how<br />

PCD tools are sharpened in one set-up with the VHybrid 260<br />

grinding and erosion machine. The visible result are the reflective<br />

surfaces, which are otherwise only possible with<br />

time-consuming and cost-intensive grinding work. Thanks<br />

to the V@ boost solution, it will be possible in future to<br />

integrate the erosion into the tool manufacture as a complete<br />

manufacturing process. Tool manufacturers can use<br />

the VHybrid 260 to machine as usual with reliable process<br />

management in an unmanned operation.<br />

Eroding and grinding up to 100 % each time<br />

In general the VHybrid 260 can be used to grind or erode<br />

both carbide and PCD tools up to 100 % in one set-up. The<br />

VHybrid 260 is based on multi-layer machining, which is<br />

implemented using two vertically arranged spindles. Here<br />

VOLLMER is using the tried-and-tested technology of its<br />

VGrind grinding machine series. With the VHybrid 260, the<br />

bottom spindle can be used both for grinding and for eroding,<br />

while the top spindle is reserved exclusively for grinding.<br />

The visible result of the new V@ boost solution for<br />

Vollmer’s VHybrid 260 machine is mirror-like surfaces<br />

on the cutting edges, previously only possible with<br />

complex and cost-intensive grinding operations<br />

Standard and special tools can be flexibly ground and<br />

eroded – regardless of whether the blanks consist of carbide,<br />

PCD or soldered PCD plates. The machine can be used for<br />

tools with Ø of up to 150 mm and lengths of up to 360 mm.<br />

The unmanned, round-the-clock machining allows for various<br />

automation solutions: meaning that the HC4 Plus chain<br />

magazine can hold up to 53 HSK tools, for example. In addition<br />

up to eight grinding and eroding wheels, including coolant<br />

supply, can be switched fully automatically.<br />

further information: www.vollmer-group.com<br />

no. 4, November <strong>2022</strong><br />


processes<br />

Making industrial production more flexible,<br />

more productive, and more sustainable<br />

Maximum productivity and sustainability,<br />

with flexible machine solutions for<br />

many different production tasks and sectors<br />

– this summarizes best the EMAG<br />

Group’s focus for this year’s presence at<br />

AMB in Stuttgart. At the trade fair the specialists<br />

presented their technological scope,<br />

from turning, grinding, and hobbing<br />

to robot-based automation to laser and<br />

ECM machining. And data-based analysis<br />

and optimization of production process<br />

will continue to be a key focal point<br />

at EMAG. Accordingly, visitors got to<br />

see a range of IoT products that can, for<br />

example, reveal the energy consumption of<br />

a machine or its status.<br />

Under the name EDNA (short for “EMAG<br />

DNA”) the machine manufacturer has been advancing<br />

data-based networking of its production<br />

solutions since years. This makes it possible,<br />

for example, to determine the status and OEE<br />

values of a machine with great accuracy and get<br />

information on its current production output.<br />

At AMB EMAG presented the next IoT development<br />

step – an energy monitor with which an<br />

unusual high energy consumption (for example<br />

per workpiece) can be detected any time. “Sustainability<br />

through transparency,” is the motto.<br />

In these days, with the world facing a climate<br />

and a growing energy crisis, this is becoming increasingly<br />

important.<br />

Combination as the recipe for success<br />

The mechanical engineering solutions shown by<br />

EMAG are similarly efficient and sustainable.<br />

Electromobility in focus: visitors were shown a<br />

turnkey manufacturing line for rotor shafts and<br />

laser coating of innovative brake disks<br />

From the product range of EMAG Weiss, the<br />

W 11 CNC universal cylindrical grinder could be seen at AMB<br />

The SG 160 from EMAG SU is particularly impressive. It machines turn<br />

blanks in a completely dry process that combines hobbing and gear<br />

generating grinding in a single clamping operation. Subsequently these<br />

gears are nitrided and after the drilling work is completed, they are finished<br />

on a turning machine. This not only saves an enormous amount of<br />

space in the manufacturing hall, but also reduces the investment costs<br />

greatly, as this process would customarily require separate machines for<br />

hobbing and generating grinding respectively. Additionally, the process<br />

time is much shorter than when using individual processes, because<br />

both processes are fine-tuned to each other. The new machine makes use<br />

of two procedures on two different tool spindles: hobbing for the soft machining<br />

and dry generating grinding (finish grinding). A huge amount of<br />

electrical energy is saved in the manufacturing, since the alternative – wet<br />

grinding – always necessitates a filter system, cooling and oil mist extraction.<br />

These “energy guzzlers” are not necessary for dry machining with<br />

the SG 160.<br />

The VLC-GT series, presented by EMAG at AMB, offers a similar combined<br />

machining operation. With these machines different technologies<br />

such as hard turning, internal and external grinding, milling, reaming, or<br />

honing can be combined, and the machining in a single clamping operation<br />

ensures that the components are of high quality. Using the pick-up<br />

principle and combination machining, not only chucked components but<br />

also short shaft parts can be produced on the VLC 200 GT.<br />

Efficient machining of large components for<br />

commercial vehicles<br />

A literally large solution in the field of vertical turning is the VSC 500,<br />

which EMAG demonstrated live at the AMB – a platform for the production<br />

of large and very heavy workpieces, such as those found in the commercial<br />

vehicle sector, from brake drums, transmission and engine components<br />

to wheel hubs. These components undergo turning, drilling, sinking,<br />

reaming, milling, and threading processes in the very rigid machine,<br />

depending on the specific requirements. Even more productivity is guaranteed<br />

by the DUO variant for machining in two clamping operations<br />

(OP 10/OP 20).<br />

36 no. 4, November <strong>2022</strong>

processes<br />

The new automation cells with robots ensure fast,<br />

cost-efficient, and reliable production processes;<br />

EMAG provides different configuration options:<br />

Automation cell with basket stacking: here the loading and<br />

unloading operations of the system make use of baskets from<br />

which the robot grabs the pre-aligned workpieces or deposits<br />

them; the empty baskets are placed onto a stack<br />

Bin-picking automation cell: the workpieces are in chaotic<br />

positions; with the aid of a 3D sensor system, the robot not<br />

only takes out the parts, but also correctly identifies, aligns<br />

and feeds them to the next machining step<br />

Automation cell with drawer system: the workpieces are<br />

provided on different levels; while the drawers are being filled,<br />

the robot supplies workpieces to the machine<br />

Making innovative new products possible<br />

An example of sustainable technology advanced by<br />

EMAG’s customers is electromobility, for which EMAG<br />

has provided many production solutions in the past years.<br />

At AMB the specialists presented some of these, for example<br />

a turnkey manufacturing line for a two-piece rotor<br />

shaft that is produced in a total of seven successive operations.<br />

Another technology of great interest within the context<br />

of sustainable products, is laser coating of brake discs<br />

with a machine from EMAG LaserTec, which can smoothly<br />

be integrated into complete production lines with upstream<br />

turning and downstream grinding processes. This<br />

makes it possible to create wear- and corrosion-free brake<br />

discs that produce less fine dust. Additionally EMAG<br />

LaserTec presented its new highly flexible ELC 1200 V<br />

machine platform, for individual applications from laser<br />

cleaning and laser welding to laser hardening.<br />

Large range of technologies<br />

The large range of technologies and applications mastered<br />

by the EMAG Group was showcased at AMB for example<br />

in the form of the W 11 CNC cylindrical grinder from<br />

EMAG Weiss, which enables extremely precise machining<br />

of individual parts, prototypes and small series, as well<br />

as the VTC 200 CD shaft turning machine, which features<br />

a center drive for simultaneous 4-axis machining with<br />

short cycle times. Additionally the K 160 hobbing machine<br />

demonstrated that EMAG’s range of effective production<br />

solutions is not limited to the automotive industry:<br />

the machine is ideal for small gearing up to module 2.5,<br />

such as those used in hand tools, for example cut-off saws.<br />

Electrochemical machining (ECM) also plays an important<br />

role in a wide variety of industrial sectors. EMAG’s<br />

specialists have created a solution for manufacturing<br />

complex internal geometries or internal gearing – and<br />

high-strength materials or large quantities are no problem<br />

at all.<br />

New automation cells<br />

Another focal point at EMAG’s trade fair booth was the<br />

topic of automation, because the machine manufacturer<br />

from the south of Germany has developed new automation<br />

cells with robots. The entire production process is getting<br />

faster, more cost-efficient and more reliable, with the<br />

pick-up technology from EMAG being particularly suitable<br />

for this approach as the machines have an internal<br />

automation system, which serves as a good basis for<br />

having them loaded and unloaded by robot solutions.<br />

The parts are, for example, fed pre-aligned in baskets or<br />

drawers, chaotically as bulk cutoffs or by means of infeed<br />

and outfeed conveyors.<br />

Currently an overall change in the production conditions<br />

of many companies is in progress: modern technology<br />

and changed applications increasingly lead to more<br />

complex components. Additionally the price pressure is<br />

getting stronger and the demands for energy-efficient<br />

processes are getting louder. EMAG demonstrated how<br />

these requirements can be met.<br />

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

no. 4, November <strong>2022</strong><br />


machining center<br />

The leader in<br />

complete machining<br />

At AMB <strong>2022</strong> WFL Millturn Technologies presented<br />

the new M20 MILLTURN complete machining center<br />

for the first time. Alongside gear skiving technology,<br />

there is a clear trend toward automation and the<br />

integration of sensors. The latest solutions from WFL<br />

range from smart software to screw programming<br />

through to intelligent tools and clamping devices.<br />

WFL is the only manufacturer worldwide that concentrates<br />

exclusively on the production of multifunctional complete<br />

machining centers. In many high-tech companies today, the<br />

trade name MILLTURN stands for the central machine tool<br />

for the production of complex components with the highest<br />

precision.<br />

The M20-G showcased at AMB is equipped with an innovative<br />

automation solution – the intCELL. The integrated production<br />

cell is fitted on the right-hand side of the machine,<br />

the workpieces are supplied on a strip accumulator. With<br />

the integrated loading concept WFL has reduced the space<br />

requirement by 50 % in comparison to a conventional production<br />

cell. The M20’s integrated loading feature is designed<br />

for chuck parts with a Ø of up to 300 mm and a workpiece<br />

weight of 15 kg. For shaft parts a workpiece Ø 100 mm and<br />

a workpiece length of 300 mm is possible.<br />

The turning-boring-milling unit with integrated spindle<br />

motor and a B-axis with torque motor are entirely new features.<br />

The individual tool holder with B-axis on the lower<br />

slide is another highlight. The upper and lower system can<br />

be used simultaneously and both systems are supplied by a<br />

reliable and dynamic tool changer from a shared magazine.<br />

This allows even complex components to be machined with<br />

optimal efficiency, and the setup of the tool turret is no longer<br />

necessary. The tool can be moved up to 100 mm below the<br />

turning center, so drill patterns with Ø of up to 200 mm can<br />

be produced on the face with a high level of precision and<br />

without turning the C-axis.<br />

Five-axis machining is planned precisely, right down<br />

to the last detail, to ensure smooth production of<br />

turbine blades on a MILLTURN from WFL<br />

Universal machining solutions<br />

with the M50-G MILLTURN<br />

The new M50-G MILLTURN generation, with greater center<br />

distance and improved performance, was another highlight<br />

of AMB. The optional center distance of 6000 mm enables<br />

efficient machining of long shaft parts. When designing the<br />

M50, WFL implemented some of the features of the larger<br />

M80. The machine’s existing potential is fully utilised, particularly<br />

in terms of the increased drive power, combined with<br />

the HSK-A100 or Capto C8 tool accommodation. The turning<br />

Ø is available up to 670 mm and the fully developed, proven<br />

machine concept of the M50 MILLTURN has received an<br />

attractive ergonomic finish. A separate pick-up magazine<br />

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

with a length of 1600 mm can be automatically inserted and<br />

changed. The standard disc magazine can be expanded to up<br />

to 200 positions.<br />

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

Components such as turbine blades or plasticising screws require<br />

both dynamic and stable machining concepts. A special<br />

clamp from the manufacturer Grasch was used to clamp<br />

rectangular raw materials easily and securely, a fundamental<br />

requirement when machining turbine blades. Technologies<br />

known as ‘helical spiral milling’ and ‘helical longitudinal<br />

milling’ are used to machine the blade.<br />

Smart tools: ICOtronic and ultrasound measuring<br />

The sensors of the ICOtronic tool provide information on the<br />

machining process as close as possible to the cutting edge.<br />

This optimises milling processes and also increases the machines’<br />

productivity, as shown at AMB.<br />

Integrated production cell for automatic loading<br />

and unloading: intCELL<br />

Ultrasound measuring was also demonstrated live at the<br />

trade fair. The automatically loading ultrasound measuring<br />

probe enables a fully automated measuring process. The large<br />

measuring range (1.5 - 30 mm) offers further benefits. Ultrasound<br />

measuring is extremely well suited for calculating the<br />

hole run-out and Ø of very deep holes.<br />

further information: www.wfl.at<br />

38 no. 4, November <strong>2022</strong>

machining center<br />

360° solutions for successful future manufacturing<br />

HELLER’s trade fair appearance at AMB focused<br />

on 360° performance – a holistic view of the requirements<br />

of modern manufacturing. Based on this principle<br />

the machine tool manufacturer wants to provide<br />

customers with successful solutions helping them<br />

to produce reliably and at competitive per-piece costs<br />

in day-to-day manufacturing – with maximum availability<br />

and productivity – even in challenging times.<br />

Full spectrum of productivity –<br />

HELLER machines at AMB<br />

With the H 4000 and HF 5500, HELLER showcased the latest<br />

generation of highly productive 4-axis and 5-axis machining<br />

centers at AMB. 2020 the company already launched the<br />

second generation of the horizontal 5-axis machining centers<br />

from the HF series. The goal of this further development was<br />

to enable an even more universal application, both in single-part<br />

and series production. In addition to the existing<br />

options of interpolation turning and the use of the HELLER<br />

out-facing head system, the company now also offers a swivelling<br />

NC rotary table with turning function especially for<br />

the HF 5500 exhibited at AMB to cater to the various requirements<br />

in terms of complete machining. The prerequisites for<br />

this turning function are enforced drives in Z and A. The<br />

enforced Z-axis is equipped with two ball screws and two<br />

direct driven absolute measuring systems combined to a<br />

gantry-drive system. Moreover, the HF 5500 is equipped with<br />

a DDT (Direct Drive Turning) rotary table, a spindle with<br />

locking function for secure fixing of turning tools, the balancing<br />

technology cycle and with Siemens NC turning cycles.<br />

The 4-axis machining center model H 4000 is the fourth<br />

generation of the H series to be launched in the market. The<br />

machining center is equipped with the SPEED equipment<br />

package for minimal idle times and highest dynamics, the<br />

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

and a chain-type tool magazine with 80 storage places. In<br />

Rotary pallet storage<br />

particular, manufacturers and suppliers from the broad<br />

industrial sector (including machine builders, contract<br />

manu facturers, energy and fluid technology companies) are<br />

using the horizontal 4-axis machines for the production of<br />

medium to large volumes.<br />

Automation solutions from HELLER –<br />

flexible, value-adding, competitive<br />

The main purpose of automated manufacturing and production<br />

centers is the reduction of idle times in order to optimise<br />

system availability. For this purpose HELLER offers proprietary<br />

automation solutions that can be optimally combined<br />

with the highly productive HELLER machining centers. Due<br />

to the wide variety of market requirements this portfolio is<br />

complemented by a range of specialised solutions HELLER is<br />

able to offer, based on best-in-class partnerships.<br />

The aforementioned H 4000 is equipped with a flexible<br />

robot automation from HELLER. The robot cell, equipped<br />

with a Gressel gripper system, is used for workpiece loading<br />

to the machining center and enables flexible workpiece<br />

handling. A workpiece storage system to ensure unmanned<br />

shifts was shown along with a demonstration of the user<br />

interface for easy and intuitive operation of the solution.<br />

HELLER also presented the RSP 12H2 rotary pallet storage.<br />

With a total of eleven pallet storage locations the automation<br />

solution enables flexible and automated handling of machine<br />

pallets and is predestined for series production of small and<br />

medium batch sizes.<br />

Equipped for the factory of the future – digitisation<br />

In the context of Industry 4.0 and digitisation in production,<br />

HELLER developed years ago an innovative concept that<br />

further increased the productivity of HELLER machining<br />

centers, for example through extended functionalities and<br />

service options.<br />

HELLER out-facing head<br />

further information: www.heller.biz<br />

no. 4, November <strong>2022</strong><br />


machining center<br />

Seen at IMTS<br />

ANCA launches its premium,<br />

next generation machine range<br />

The new MX7 ULTRA can manufacture large volumes of endmills<br />

and other cutting tools of the highest accuracy and quality.<br />

The minute size of a micron is beyond the human eye, but in becoming<br />

even more precise and moving from micrometers to nanometers,<br />

ANCA offers the highest accuracy and quality in a cutting<br />

tool in the market. New software, hardware and design features are<br />

combined to make significant advances in surface finish, accuracy<br />

and controlled runout, to deliver batch consistency from the first<br />

ground tool to the thousandth.<br />

Highest quality and performace cutting tools with MX7 ULTRA<br />

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

in precision machine design and will change the industry expectations<br />

for accuracy and tool life. Achieving these outstanding results has only<br />

been possible because of our extensive experience working with customers to<br />

manufacture the highest quality cutting tools over many years. At ANCA we<br />

are always designing and innovating to find better customer solutions and I<br />

am very proud of the ANCA team that has developed the MX7 ULTRA.”<br />

Automation on MX7 ULTRA with<br />

ANCA’s Robomate<br />

“The ULTRA machine is truly market changing. It is the culmination of<br />

ANCA’s elite technology, deep industry knowledge and customer experience<br />

in grinding,” says Thomson Mathew, ANCA product manager for the MX<br />

series and software products.<br />

Unlike its competitors ANCA is vertically integrated. This provides a significant<br />

advantage as it means ANCA teams can develop and manufacture<br />

their own machines from base to canopy – including controls and drive<br />

systems, design and simulation software and even machine monitoring software.<br />

Owning all the technology means engineers and designers can consider<br />

the entire machine as a single system when developing new solutions.<br />

“We wanted to create technology that could produce premium cutting tools<br />

that are above the current market standard in both accuracy and tool life. We<br />

introduced nanometer resolution into our axis, which is new to the cutting<br />

tool market. The result is a perfect example of ANCA’s vertical integration<br />

capabilities as we have the in-house ability to fine tune or develop the new<br />

algorithms for our drives to make this happen.”<br />

Quality from every angle with MX7 ULTRA<br />

40 no. 4, November <strong>2022</strong>

machining center<br />

“Cutting tools like ballnose, corner radius, barrel shape<br />

ballnose and double corner radius endmills are used widely<br />

across industries including diemold, aerospace and power<br />

generation. The surface finish quality, accuracy and runout<br />

are critical for the performance and cutting life in all applications<br />

– so our customers want a guarantee that their first tool<br />

will be exactly the same as the hundredth, or thousandth.<br />

The MX7 ULTRA can produce high quality cutting tools to<br />

suit all customer needs to satisfy all industry types.”<br />

The MX7 ULTRA superior performance highlights<br />

➢ greater control for the velocity and acceleration or<br />

deceleration along with machine jerk limits:<br />

To increase the stiffness of the C-axis, the MX7 ULTRA<br />

combines developments to the nanometer or micro<br />

degree resolution in the linear and rotary axis,<br />

tuning parameters, several system enhancements<br />

and major mechanical changes.<br />

➢ ULTRA-fast response to internal or<br />

external disturbances:<br />

ANCA’s newly designed servo control algorithm allows<br />

silky smooth motion of an axis with the use of a unique<br />

algorithm and nanometer measurement in the control<br />

system. This will create finer cutting edges and<br />

eliminating micro-chips making it more efficient<br />

while used in actual machining of materials.<br />

➢ better cycle time and higher productivity<br />

of high-quality cutting tools:<br />

The unique algorithm is key to the performance of the<br />

machine and ensures outstanding tracking performance.<br />

It also allows ULTRA-performance of the servo system<br />

without using a complex, complicated or expensive<br />

mechanical system.<br />

➢ reduces setup times and scrap:<br />

Cutting-edge software has been developed by ANCA to<br />

ensure batch consistency in large volumes. LaserUltra<br />

is part of the MX7 ULTRA package to maintain<br />

consistency and accuracy of the grinding process which<br />

includes in-process measurement and compensation to<br />

accommodate wheel wear and other external variations<br />

during large batch grinding. Its analog capability can<br />

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

profile which includes ballnose and corner radius tools.<br />

The MX7 ULTRA includes:<br />

▶ nanometer control system<br />

▶ new servo control algorithm for smooth motion<br />

▶ system and mechanical upgrades enhance<br />

stiffness and rigidity<br />

▶ in-process measuring, balancing and runout<br />

compensation for consistent accuracy<br />

▶ Motor Temperature Control (MTC) – compensation<br />

for thermal expansion on the grinding spindle,<br />

and specialist training support in how to grind<br />

industry leading cutting tools<br />

Tool runout compensation on MX7 ULTRA<br />

➢ increased wheel life and better-quality tools:<br />

Tool and wheel performance can be further optimized by<br />

the iBalance software, which guides a user to the optimal<br />

grinding position and RPM for vibration monitoring and<br />

balancing the wheelpack inside the machine. Correctly<br />

balanced wheelpacks result in superior surface finish and<br />

reduced wheel wear due to the elimination of wheel<br />

vibration.<br />

➢ consistency in finished tool quality:<br />

A major inclusion in the MX7 ULTRA package is the<br />

total tool runout measurement and compensation<br />

operation in iGrind. When an endmill is in rotation it is<br />

important that each tooth hits at the exact same spot along<br />

the workpiece for longer tool life and efficient cutting.<br />

Every tool in the batch can be measured and compensated<br />

for runout to make sure the entire batch is within a<br />

tolerance of 0.002 mm. It is another piece of assurance<br />

that the first endmill will be as good as the last.<br />

➢ consistent spindle thermal stability:<br />

Motor Temperature Control (MTC) is a patented<br />

(US PAT. 11,394,331) innovation built into the motor<br />

spindle drive firmware. Smart control algorithm actively<br />

manages and maintains the temperature of motorized<br />

spindles in the MX7 ULTRA. Dramatically reduced<br />

machine warmup time means production can start sooner,<br />

once the machine has reached thermal stability. This<br />

improves productivity and machine use. Consistent<br />

thermal stability of the spindle over time regardless of<br />

changes in load or speed, or coolant temperature, greatly<br />

improves the dimensional stability of grinding results.<br />

➢ post grinding processes:<br />

The smoother, finer cutting edge and surface finish as<br />

a result of the combination of all the above including<br />

the nanometer control will assist in all post grinding<br />

applications like edge preparation and coating. A finer<br />

edge that has been properly prepared has greater stability,<br />

which reduces the likelihood of it chipping, while also<br />

decreasing surface roughness which can cause increased<br />

friction between the tool and the workpiece.<br />

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

no. 4, November <strong>2022</strong><br />


machining center<br />

The answer to new requirements?<br />

New solutions<br />

This year’s AMB in Stuttgart was all about ‘Smart<br />

Manufacturing Solutions’ for SW. Trade fair visitors<br />

could expect an exciting insight into the company’s<br />

product highlights, including a world premiere with<br />

which the global player goes beyond the standards of<br />

the manufacturing industry.<br />

“We see ourselves not only as a ‘machine provider’, but<br />

rather as a ‘solution provider’ that offers its customers intelligent,<br />

digitally networked, energy-efficient and future-proof<br />

manufacturing solutions. In other words, we provide ‘Smart<br />

Manufacturing Solutions’ consisting of our proven standard<br />

machine portfolio, modular automation modules and digital<br />

services,” explains marketing manager André Harter. Setting<br />

new benchmarks and actively shaping the future of the industry<br />

is the vision. Rapidly changing requirements in new<br />

industries such as e-mobility are opening up new potential<br />

for manufacturing solutions, which SW knows how to address.<br />

A SW expert provided information on these and many<br />

other topics in live talks in front of a six-meter LED wall at<br />

the trade show booth.<br />

World premiere:<br />

produce larger parts with the same footprint<br />

A special highlight at AMB <strong>2022</strong> was the world premiere<br />

of the new BA 711 space, a flexible single-table machine for<br />

small and medium series production of precision parts made<br />

of cast iron, cast steel or steel.<br />

“The machine’s footprint is almost identical to previous<br />

models. But the new design eliminates the partition wall<br />

in the machine interior, so the space available in the machine<br />

has been expanded enormously,” explains Harter. The<br />

BA 711 space has effectively not become any larger, but now<br />

it can machine considerably larger parts such as engine<br />

blocks, chassis parts or transmission housings for agricultural<br />

and construction machinery, trucks, rail vehicles and<br />

much more.<br />

Looking to the future:<br />

why multi-spindle machines and<br />

automation modules are the right choice<br />

lndustries such as e-mobility in particular place great demands<br />

on manufacturers in terms of flexibility and future<br />

viability. SW has been successfully supporting its customers<br />

in these areas for years and has always focused on<br />

The new SW single-table machine BA 711 space for<br />

small and medium batch production<br />

multi-spindle machining centers. This year at AMB, for<br />

example, the benefits of energy-efficient multi-spindle machines<br />

were once again presented. “A four-spindle machine<br />

shortens cycle times by up to 60 % compared to singlespindle<br />

machines. At the same time it saves around 70 % of<br />

the floor space and consumes only about half the amount<br />

of energy,” says André Harter, citing important factors for<br />

a future-proof and sustainable investment. The latter in<br />

particular is ensured by the fact that SW also supports its<br />

customers with customized automation solutions that can be<br />

flexibly retrofitted. “We focus on reducing non-productive<br />

time, increasing quality, and improving ergonomics. With<br />

a modular system divided into hardware and software, we<br />

always find the optimum solution.”<br />

Market innovation:<br />

one interface for everything – made by SW<br />

SW is increasingly distinguishing itself as a solution provider<br />

and holistic system partner. An important key component<br />

is digitally networked communication for optimum interaction<br />

between the machines, systems and optionally available<br />

add-on modules. For example in order to be able to integrate<br />

energy-carrying tools into the machine tool easily and independently<br />

of the manufacturer, SW presented an in-house<br />

development at AMB: the HSKi spindle. “Our services range<br />

from intelligent interfaces for connecting external add-on<br />

modules with the help of our HSKi spindle to software programs<br />

and cloud solutions that enable greater transparency<br />

and data availability during manufacturing processes – that’s<br />

what we call ‘life data’ at our company,“ says Harter, summarizing<br />

the wide range of process optimization options.<br />

further information: www.sw-machines.com<br />

42 no. 4, November <strong>2022</strong>

machining center<br />

The perfect machine for the entry-level segment<br />

STUDER S100 universal internal cylindrical grinding machine<br />

High-precision, flexible and reliable: with the new S100,<br />

STUDER presents the ideal universal internal cylindrical grinding<br />

machine for the entry-level segment. Its excellent price-performance<br />

ratio makes it the perfect machine for a wide range of internal<br />

grinding applications.<br />

“The S100 internal grinding entry-level machine perfectly complements<br />

our comprehensive internal grinding portfolio”, explained CSO Sandro<br />

Bottazzo, when presenting the S100 at BI-MU Exhibition for Machine Tools<br />

in Milan.<br />

Like all STUDER cylindrical grinding machines, the S100 has also a<br />

machine bed made of Granitan®. Its outstanding dampening, and thermal<br />

characteristics ensure consistently good<br />

grind ing results and the renowned STUDER<br />

precision. During the development special<br />

attention was given to a simple and efficient<br />

design of the components, making operation<br />

and maintenance easier for the operator.<br />

However, the equipment of the S100 also<br />

makes it suitable for grinding a universal<br />

spectrum of parts comprising of geometrically<br />

defined basic forms and contours, which<br />

can be generated with interpolating axes.<br />

Flexible equipment ensures a<br />

diversity of parts<br />

The machine can be equipped with up to two<br />

internal grinding spindles or one internal and<br />

one external spindle. In addition to a fixed<br />

wheelhead, it can be equipped with a manual<br />

with a 2.5 degree Hirth and, in its optimum<br />

configuration, with an automatic wheelhead<br />

with 1 degree Hirth. A synchronous motor<br />

drives the grease-lubricated internal and external<br />

belt spindles. The machine is operated<br />

by the Fanuc 0i-TF PLUS controller, together<br />

with the proven STUDER operating system.<br />

A further advantage of the S100 is the automation<br />

option. On request it can be equipped<br />

with a loading interface and an automatic<br />

sliding door, enabling automatic operation<br />

and the production of large series.<br />

Typical workpieces for production on the<br />

S100 include collets for toolmaking, bearing<br />

rings, ball bearings and cylinders, as well as<br />

hydraulic control valves in small series.<br />

External and internal machining of flange<br />

parts or grinding of threads or non-circular<br />

forms is also possible. The competent and reliable<br />

STUDER Customer Care is naturally<br />

also on hand to provide advice and technical<br />

support for the S100.<br />

STUDER S100 wheelhead 1× internal grinder 1× external grinder<br />

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

no. 4, November <strong>2022</strong><br />


components<br />

AMB premiere for the smart chuck jaw<br />

From now on, clamping is smart: Röhm, the<br />

clamping and gripping specialist based in Sontheim<br />

an der Brenz (Baden-Württemberg, Germany),<br />

presented its world premiere iJaw at AMB in Stuttgart.<br />

It is the first chuck jaw ever to be equipped with sensor<br />

technology and wireless data transmission. It allows<br />

the clamping force to be measured in real-time directly<br />

during machining. Data is transmitted to a gateway<br />

via the industry standard IO-Link Wireless.<br />

Great news: OEMs (the original equipment manufacturers)<br />

can now integrate a smart chuck jaw into their machines and<br />

PLC controllers displaying clamping forces on their HMI (human<br />

machine interface) displays. iJaw development partner<br />

DMG Mori is so enthusiastic about the functionalities that<br />

its machine tools can now be configured with iJaw. Other<br />

partners, such as WFL Millturn, Mazak and Emco also presented<br />

machines with iJaw applications at AMB in Stuttgart.<br />

But existing inventory can also be updated to smarter<br />

clamping with a retrofit “On-Premises” interface and display<br />

independent of the machine’s electronics. This after market<br />

iJaw upgrade is also available for most non-Röhm quick<br />

change jaw chucks.<br />

Available geometries of the iJaw<br />

Revolution in metalworking<br />

“With iJaw we are effectively revolutionizing the manufacturing<br />

process in metalworking. This is because real-time measurement<br />

of the clamping force during the machining process<br />

provides the user with a whole range of benefits. This starts<br />

with higher machine availability because setup times can be<br />

reduced and machining processes accelerated. This reduces<br />

part costs on the one hand, while part quality increases on<br />

the other. This is pure process optimization and a real milestone<br />

in the digitalization of manufacturing. Overall, sensorcontrolled<br />

workpiece machining is, of course, much safer<br />

than conventional manual clamping by feel,” says Gerhard<br />

Glanz, CEO of Röhm GmbH.<br />

Safety even with thin-walled workpieces<br />

Gone are the days when the clamping force was set higher<br />

than necessary in order to play it safe. “Especially with<br />

thin-walled components or sensitive surfaces, this is known<br />

to be counterproductive because too much clamping force<br />

here quickly leads to deformation or even crushing of the<br />

workpiece. You can significantly reduce rejects with precise<br />

sensor-controlled machining,” says Glanz.<br />

Structure of the sensorized clamping jaw iJaw from Röhm<br />

This is how the iJaw works: The forces applied by the jaw<br />

are detected by an integrated sensor and the data is transmitted<br />

and processed accordingly. The iJaw measures not only<br />

the actually applied forces of the internal and external clamping<br />

but also its own temperature. The charging status of the<br />

battery is also always visible. If data from the pressure display<br />

is available, the iJaw can also be used to monitor the condition<br />

and efficiency of the power chuck. The iJaw measures in<br />

real-time during machining. For this purpose, it has a suitably<br />

robust hardened steel and waterproof (IP 68) design. The<br />

transmitting antenna has a cover made of high-temperature<br />

resistant plastic to protect against glowing chips.<br />

44 no. 4, November <strong>2022</strong>

components<br />

Retrofitting made easy<br />

It will soon be possible to very easily<br />

retrofit machine tools iJaw. In addition<br />

to installing the chuck jaws with<br />

integrated sensors, users only need<br />

the gateway with an adjacent industrial<br />

processor and a display for<br />

accessing the data. This can be an<br />

instaled PC or a mobile tablet. The<br />

system is then controlled by the iJaw<br />

Mobile web app that establishes the<br />

connection between the iJaw and<br />

the gateway. “Through iJaw Mobile<br />

users can then create jobs, manage<br />

their jaws, and, of course, receive<br />

alerts, for example if the minimum<br />

clamping force is not reached,”<br />

explains Glanz.<br />

With the “iJaw Mobile” app, the iJaw is controlled and<br />

clamping force data is visible in real time<br />

Gateway as a data hub<br />

The iJaw transmits the measured data wirelessly to a gateway via the robust IO-Link<br />

Wireless protocol with a high sampling rate of 100 Hz.<br />

The gateway consists of an industrial PC for data processing and interfaces and<br />

the IO-Link Wireless Master. The gateway communicates with the iJaw via IO-Link<br />

Wireless technology. The data is transferred either via ethernet to a processor via the<br />

integrated LAN interface and then accessible via WiFi for On-Premises displays. Of<br />

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

purpose, the gateway is connected to the machine via the integrated Profinet interface.<br />

The machine controller can process the data in real-time and display it on the<br />

machine panel. The universal iJaw gateway from Röhm uses only standard protocols<br />

and interfaces. Their specification is freely accessible. Further sensors – your own or<br />

also from third-party suppliers – can be integrated with the universal gateway without<br />

additional hardware.<br />

Clamping force curve of a component in the series process –<br />

the deviation at the end indicates irregularities<br />

Soon available in the cloud:<br />

the digital fingerprint<br />

of machining<br />

The option of utilizing cloud services<br />

with the iJaw system will also soon be<br />

available. This will enable additional<br />

functions such as process or productivity<br />

analyses and the docu mentation<br />

of large quantities of measurement<br />

data. With the iJaw Mobile app<br />

users can thus access the data from<br />

anywhere and evaluate processing<br />

parameters or have warning messages<br />

displayed. “Especially in the<br />

production of components with<br />

mandatory documentation, such<br />

as aerospace manufacturing, this is<br />

a very attractive feature. The iJaw<br />

archives the digital fingerprint of the<br />

machining process, so to speak,” says<br />

Glanz.<br />

Flexible in use<br />

The iJaw can be mounted and used<br />

on all lathe chucks with a suitable<br />

(standard) jaw interface like any<br />

other chuck jaw. For the market<br />

launch, the iJaw is available as a<br />

single-stage jaw, two-stage jaw, and<br />

block jaw for lathe chucks with<br />

straight gearing in the sizes 260, 315,<br />

and 400 as well as a special jaw for<br />

independent chucks. One such chuck<br />

from Röhm is the Duro-A RC power<br />

chuck with the quick jaw change<br />

feature. Various interchangeable<br />

hard and soft clamping inserts are<br />

locked onto the jaws with screws to<br />

adapt the jaws to different workpiece<br />

geometries.<br />

further information: www.roehm.biz<br />

no. 4, November <strong>2022</strong><br />


components<br />

A whole new range of products dedicated to rotary<br />

Rollix, department of the Defontaine Group,<br />

announced the launch of its new range: Rollix RT.<br />

Highly focused on innovation, Rollix’s R&D teams<br />

have developed the Rollix RT product range to satisfy<br />

all industrial companies with rotary tables, indexing<br />

tables, machine tool tables, machining centers, milling<br />

and drilling machines. Rollix offers this range of dedicated<br />

rings from 200 to 1,030 mm.<br />

“Rollix has been the European leader in slewing rings and<br />

bearings for more than 40 years,” explains Nicolas Charron,<br />

sales director for the Rollix brand within the Defontaine<br />

Group. He adds: “With Rollix RT we are expanding our range<br />

of precision bearings. After the Compact CB, Compact HP<br />

& P, Compact XL and Compact Light ranges, the RT range<br />

offers slewing rings to specifically meet the machining precision<br />

and performance needs of machine tools. We target<br />

both new machine providers and the aftermarket. Finally, our<br />

stock strategy allows us to make immediate deliveries.”<br />

The main strengths of the range are:<br />

→ interchangeability with the standard references on the<br />

market: similar speed range, identical precision<br />

→ longer life than the market average, if used and maintained<br />

correctly<br />

→ 5 year parts warranty on<br />

new machine tools<br />

Technical characteristics<br />

of the Rollix RT range:<br />

→ very high rigidity<br />

→ high rotational accuracy<br />

→ high geometrical quality<br />

→ high tilting moment capacity<br />

→ range from 200 to 1,030 mm;<br />

→ sable from - 25° C to + 120° C.<br />

Made of 100c6 steel, each<br />

product in the Rollix RT range<br />

is composed of three rows of rollers.<br />

Rollix is committed to maintaining its<br />

customers’ productivity<br />

Rollix RT slewing rings are ideal for applications requiring<br />

high positioning accuracy. Rollix teams are committed to<br />

short lead times and availability of its range in France and<br />

on the five continents thanks to its distributors network for<br />

reduced supply times. In addition to these commitments,<br />

Rollix offers optimal customer service to maintain the productivity<br />

of its customers’ production lines. The Rollix<br />

RT range is available on the Rollix e-shop for instant order<br />

processing whatever the time zone.<br />

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

Three jaws for perfection<br />

The success story of the TANDEM3 modular<br />

system continues – the new 3-jaw clamping force block<br />

offers even greater design freedom for automated<br />

machine loading in four actuation variants.<br />

All TANDEM3 power clamping blocks are distinguished by<br />

their high clamping force and accuracy, together with a compact<br />

design. This makes them the ideal companion for process-reliable<br />

workpiece clamping in confined spaces. Various<br />

pneumatic monitoring functions, optional clamping force<br />

amplification for pneumatic actuation and an extensive range<br />

of accessories make them perfectly suitable for automated<br />

use in the metal cutting industry. This makes the TANDEM3<br />

clamping force block the ideal companion for small and extremely<br />

large batch sizes in all industries.<br />

Four variants for cylindrical clamping<br />

The new 3-jaw clamping force block constitutes a further<br />

module for stationary clamping of cylindrical workpieces<br />

for the TANDEM3 series. Even force distribution ensures secure<br />

and repeatable clamping. Like its 2-jaw counterpart, it<br />

also comes with a sophisticated lubrication system that ensures<br />

high efficiency and constant clamping forces. The optimized<br />

external contour ensures controlled diversion of chips<br />

and means the workpiece is easily accessible in any machining<br />

operation. Additional cover<br />

plugs prevent the clogging of<br />

chip clusters. The clamping device<br />

is available in pneumatic<br />

(KRP3), hydraulic (KRH3),<br />

spring-loaded (KRF3) versions<br />

and will soon be available<br />

in an electric version, too (KRE3). Integrated monitoring<br />

functions make the centric clamping also useable in automated<br />

machine loading. They enable the basic jaw position<br />

to be monitored via dynamic pressure or the workpiece<br />

locating surface checked reliably during automated<br />

loading for instance. By means of standardised console<br />

plates, vises can be mounted on the machine table or the<br />

VERO-S quick-change pallet system quickly and easily or<br />

flexibly interchanged.<br />

The 3-jaw vise is available as a standard or long-stroke version<br />

in four sizes from 100 to 250. Its clamping force ranges<br />

from 18 to 66.5 kN. With its extensive modular system and<br />

versatile range of accessories comprising chuck jaw, fixing<br />

and monitoring options, SCHUNK offers clamping solutions<br />

for every application.<br />

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

46 no. 4, November <strong>2022</strong>

Filtration solutions that increase efficiency<br />

and sustainability<br />

components<br />

The Filtration Division of the energy<br />

management company Eaton exhibited<br />

at Word Filtration Congress. This<br />

event is the premier global forum for<br />

scientists, engineers and practitioners in<br />

filtration and separation, it took place<br />

October 5 th -9 th in San Diego, CA. Eaton’s<br />

filtration specialists showcased numerous<br />

solutions for industrial, life sciences<br />

and hydraulic filtration applications. A<br />

special focus was placed on highly efficient<br />

water filtration solutions.<br />

One of the water filtration highlights will be<br />

Eaton’s model 2596 automatic backwashing<br />

self-cleaning strainer, a motorized unit<br />

designed to continuously remove entrained<br />

solids from liquids and pipeline systems, prevent<br />

damage to expensive pipeline system<br />

components, lower energy consumption, and<br />

minimize maintenance costs.<br />

For applications where shutting down processes<br />

is not an option, Eaton’s model 53BTX<br />

duplex strainer provides years of trouble-free<br />

service, protecting expensive pipeline system<br />

components from damage by unwanted particles.<br />

Eaton’s low maintenance DCF series was<br />

also on display. These are considered the most<br />

efficient mechanically cleaned filters on the<br />

market, operating at a consistently low differential<br />

pressure. They deliver simple, reliable<br />

operation in which a low initial investment is<br />

a key driving factor.<br />

Visitors had the opportunity to learn about<br />

the high-performing bag filters. Eaton’s<br />

TOPLINE TM single bag filter housing features<br />

a side inlet, flow through top for easy filter<br />

bag change-outs and provides optimum sealing<br />

of the filter bag. When used with the<br />

Eaton filter bags, such as DURAGAF TM ,<br />

HAYFLOW TM or MAX-LOAD TM filter bags, the<br />

filter area can be increased by up to ten times<br />

compared to a standard filter bag while minimizing<br />

environmental footprint.<br />

In addition to the water filtration technologies,<br />

Eaton also showcased filtration solutions<br />

for life sciences. This includes the upgraded<br />

BECODISC® BC activated carbon stacked disc<br />

With flow rates up to 35,000 gpm, model 2596 automatic self-cleaning<br />

pipeline strainers are ideal for applications that demand continuous flow,<br />

simplified maintenance and worry-free operation in industrial, sewage,<br />

water treatment and pulp and paper processes<br />

cartridges with BECO CARBON TM depth filter sheets that offer particularly<br />

high adsorption properties for the demanding filtration of liquids. In the<br />

realm of hydraulic filtration solutions, Eaton showed various filter elements<br />

for trouble-free operation when filtering abrasive or water-based fluids and<br />

cooling lubricants to help protect critical system components and achieve<br />

cleanliness class requirements.<br />

About Eaton’s Filtration Division:<br />

Eaton’s Filtration Division is a leader in liquid filtration that can help companies<br />

improve product quality, increase manufacturing efficiency, protect<br />

employees and equipment and help achieve sustainability goals. Worldwide<br />

Eaton employees make a difference for their customers by creating an exceptional<br />

customer experience, solving problems with application expertise<br />

and developing innovative filtration solutions. Eaton’s filtration products are<br />

manufactured and sold worldwide.<br />

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

no. 4, November <strong>2022</strong><br />


special automation<br />

Showroom for the automation of tomorrow<br />

The Liebherr Tech Center<br />

The Kempten Tech-Center of Liebherr Automation Systems provides<br />

a space for trials on high-quality automation solutions. The<br />

current focus is on vision-based robotics, bin picking and processes<br />

in battery pack assembly for e-mobility. The Tech Center is a pillar<br />

of Liebherr’s expertise and innovation potential in the field of automation.<br />

Customers benefit from the opportunity to carry out tests<br />

using their own workpieces on the equipment at the center.<br />

Complete bin picking solutions<br />

As one of the leading solution providers in<br />

the field of random bin picking, Liebherr tests<br />

the interaction of the individual components<br />

required for the automated removal of workpieces<br />

and feeding into the manufacturing<br />

line by robots at the Tech Center: software,<br />

vision systems, gripping technology and<br />

robotics. Where many other suppliers cover<br />

individual areas such as camera technology,<br />

Liebherr offers complete solutions. “We deal<br />

with all application areas and can therefore<br />

select the optimum system for our customers,”<br />

explains Thomas Mattern, development<br />

manager for automation systems. “Our portfolio<br />

includes everything from technology<br />

packages for integrators to complete robot<br />

cells as plug-and-play solutions.”<br />

But it’s not just the company’s own tests that<br />

are running at the bin picking station. Trials<br />

and feasibility studies for customers are also<br />

carried out here – from part recognition to<br />

removal with complete box emptying to<br />

position-dependent positioning in the manufacturing<br />

line (see info box). “Every workpiece<br />

has different challenges: crank shafts<br />

get caught, sheets stick to each other, anticorrosion<br />

film casts shadows or covers parts,”<br />

Mattern explains. “We can test all these<br />

scenarios really effectively here.”<br />

Position-accurate joining of high-voltage plug connections<br />

with two cooperating robots<br />

There is a concentrated atmosphere in the Tech Center. A test setup for<br />

developing gripper strategies for a customer is documented at the bin picking<br />

station. Next door the test facility is running various core processes<br />

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

an innovative solution for plugging battery module connections is being<br />

tested.<br />

Space for exchange and customer trials<br />

The 700 m 2 hall quite literally offers a great deal of space for development<br />

and innovation. There is even room for large-scale systems. Until recently,<br />

the PHS Allround 3000 had been tested here, a variant of Liebherr’s<br />

modular pallet handling system for weights of up to three tons. There is also<br />

scope for discussion and sharing ideas with customers and within the team.<br />

The test hall, customer area and meeting rooms are all under one roof allowing<br />

visitors to experience first hand the automation of tomorrow. Customers<br />

also have the opportunity to commission or carry out trials with their own<br />

workpieces.<br />

E-mobility: core processes of<br />

battery pack assembly<br />

In the field of e-mobility Liebherr is working<br />

on the end-to-end automation of battery<br />

pack assembly. The focus here is on the<br />

Bin picking – customer trials:<br />

1. scan: testing and selection of a suitable<br />

vision system with customer workpiece<br />

2. simulated removal: simulation of a<br />

workpiece-specific gripping process<br />

and checking how much the bin<br />

has been emptied<br />

3. real test removal: components are<br />

gripped in reality by a robot and a<br />

workpiece-specific gripper<br />

4. real test with loading: removal and<br />

gripping position-dependent deposit<br />

placement of the workpieces<br />

48 no. 4, November <strong>2022</strong>

special automation<br />

Automated assembly of high-voltage battery systems for e-mobility<br />

process reliability of the joining, screwing and dosing assembly processes<br />

as well as on the material flow and material supply to the assembly equipment.<br />

Liebherr tests the automation of these processes in advance as a simulation<br />

on a “digital twin” and then demonstrates the process capability on a<br />

facility test equipment.<br />

Here tests are run on the detection, positional dependency and modular<br />

assembly, module connectors and the cover of the battery housing in order<br />

to screw them in place with positional accuracy. Another focus is on the dispensing<br />

of one- and two-component adhesives and sealants as well as heatconducting<br />

pastes, including process monitoring during dispensing bead<br />

detection using 3D vision systems. “This, in combination with robotics, is<br />

a highly demanding process in e-mobility,” explains development engineer<br />

Jan Pollmann. “We are working on process reliability to pave the way for<br />

customers to automate.” Customers can also<br />

use this system by request for tests on their<br />

own battery packs, therefore benefiting from<br />

the high-tech infrastructure in Kempten.<br />

Innovative: automation of<br />

flexible plug connections<br />

A unique, innovative technology is being<br />

tested at the system over the road – the automated<br />

assembly of flexible high-voltage cables<br />

with plug connections for battery modules.<br />

Two synchronously operating robots with a<br />

patented combination gripper join the plug<br />

connections in a precise position with the<br />

aid of cameras. Interest in these connectors<br />

is growing in the industry because, unlike<br />

conventional rigid module connectors, they<br />

are easier to assemble, safer due to their electrical<br />

insulation and more robust in use. This<br />

results in additional application possibilities<br />

for the automation of plug-in cables in battery<br />

packs, which are developed and tested individually<br />

for each customer.<br />

Win-win situation<br />

The Tech Center represents Liebherr’s innovation<br />

potential in automation. Customers<br />

benefit from the extensive expertise of<br />

experts, who respond to individual requests,<br />

test products and processes in the test facilities.<br />

“Liebherr has therefore created a winwin<br />

situation for both sides,” says Thomas<br />

Mattern, summarizing the benefits.<br />

Robot cells for bin picking<br />

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

no. 4, November <strong>2022</strong><br />


special automation<br />

Well positioned at the SPS<br />

When SPS trade fair starts November<br />

8 - 10 in Nuremberg, also Aerotech, as<br />

a specialist for motion control and positioning<br />

solutions, will be there. The new<br />

release 2.3 of the motion control platform<br />

Automation1 and several linear motor<br />

stages of the PRO-Series will be on<br />

display – controlled on the booth with<br />

Automation1.<br />

Automation1 –<br />

user-friendly motion control<br />

Visitors to the Aerotech booth can see how<br />

positioning systems and peripheral components<br />

can be controlled in a user-friendly way<br />

using just one control platform. The Automation1<br />

suite replaces previous control platforms<br />

(A3200, Ensemble and Soloist) with<br />

new and more powerful features in an easyto-learn<br />

and intuitive architecture. “Our<br />

latest release 2.3 comes with several new<br />

features such as the “Machine Apps HMI development<br />

tool”. With this fully customisable<br />

tool we have replaced the previous CNC<br />

user interface and in this way revolutionized<br />

user interfaces for drive systems,” says<br />

Simon Smith, European director of Aerotech,<br />

who knows this from various tests and live<br />

installations.<br />

In addition version 2.3 of Automation1 has<br />

successfully left the beta phase and is now<br />

officially EtherCAT-compatible, which enables<br />

connection to PLC-based systems and<br />

thus expands the options for high-precision<br />

motion processes when embedded in a conventional<br />

system with lower precision. Currently<br />

still in beta, but already part of the<br />

new version are the touchscreen functions<br />

for MachineApps support and the Python<br />

API configuration interface.<br />

Automation1 also has improved data visualisation<br />

and programming module usability.<br />

Command Queue (Q-mode in A3200) and<br />

Position/Speed/Torque control via analog<br />

input have also been added and optimised.<br />

“With Automation1 2.3 we provide the users<br />

of our positioning systems with complete<br />

machine control for all components and thus<br />

go significantly further than conventional<br />

motion controls,” asserts the Aerotech<br />

European director.<br />

SPS <strong>2022</strong>: Aerotech will present its Pro-Series industrial stage series<br />

with direct-drive linear motor<br />

User-friendly control platform: “Automation1” combines usability<br />

and high-tech features in a motion control platform<br />

Linear motor stages in action<br />

Several PRO-LM linear stages controlled by Automation1 are on display at<br />

the Aerotech booth. The PRO-Series stages are available either with direct<br />

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

demonstrate our extensive know-how in the design of these linear stages,<br />

including cable management,” explains Simon Smith. “They are able to travel<br />

at high speeds with excellent speed control. It is true that not only the speed<br />

and positioning performance is a characteristic, but also the robustness.”<br />

The sealed mechanical bearings also make the PRO-LM linear stages<br />

insensitive to any kind of contamination; they are equipped with a lowfriction<br />

sealing system that substantially reduces the maintenance effort<br />

in industrial use.<br />

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

50 no. 4, November <strong>2022</strong>

impressum<br />

ISSN 2628-5444<br />

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editorial<br />

Aerotech, Inc. .......................50<br />

ANCA Pty Ltd. ..................... 40<br />


Deutschland GmbH ......... 14, 15, 25<br />

Defontaine France .................. 46<br />

EATON Corporation .................47<br />

EMAG Group .......................36<br />

FILTECH fair .......................22<br />

Fraunhofer Institute for<br />

Manufacturing Engineerig<br />

and Automation IPA ................32<br />

Fritz Studer AG .....................43<br />

Gebr. Heller Maschinenfabrik GmbH ..39<br />

Gühring KG ........................21<br />

Hartmetall-Werkzeugfabrik<br />

Paul Horn GmbH ...............16, 17<br />

Hoffmann Group .....................9<br />

IMTS fair .......................... 24<br />

company finder<br />

KYOCERA Fineceramics Ltd. .........12<br />

Lach Diamant Jakob Lach<br />

GmbH & Co. KG ............... 18, 26<br />

Liebherr-Verzahntechnik GmbH ..... 48<br />

LMT Tools GmbH & Co. KG ..........11<br />

MAPAL Fabrik für Präzisionswerkzeuge<br />

Dr. Kress KG. . . ............... 20, 23<br />

Mikron AG, Division Tool .............6<br />

MMC Hartmetall GmbH .............10<br />

Platinum Tooling Technologies, Inc. ...31<br />

Röhm GmbH Sontheim ............. 44<br />

SCHUNK GmbH & Co. KG .......... 46<br />

Schwäbische<br />

Werkzeugmaschinen GmbH ........ 42<br />


Maschinenfabrik GmbH ............35<br />

WFL Millturn Technologies<br />

GmbH & Co. KG ...................38<br />

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copyright © <strong>2022</strong> Dr. Harnisch Publications<br />

advertising index<br />

CERATIZIT Deutschland GmbH ................................inside front cover<br />

Aerotech, Inc. ..........................................................page. 11<br />

FILTECH ..............................................................page.13<br />

Lach Diamant Jakob Lach GmbH & Co. KG ............................. back cover<br />

Mikron AG, Division Tool ............................................front cover<br />

no. 4, November <strong>2022</strong><br />


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