hpt 2023 #1

ISSN 2628-5444 

high precision tooling 

Machine Tools, PCD, PVD, CVD, CBN, Hard Metal 2023 – 1 

In the future, Haas Schleifmaschinen 

will be known as Adelbert Haas. 

Who needs a Plan B when Plan A simply can’t be improved on? 

A for Adelbert. 

haas-anz-planA-Titel-hpt.indd 1 31.01.23 11:52 

■ Energy- and resource-efficient aluminum machining ■ How measurement machines and software communicate ■ 

■ Innovative use of tooling and workholding ■ Machining graphite ■ Machining centers as “green” welding cells ■

The revolution in deep grinding 

THE 

FUTURE 

IS 

YOURS 

More information 

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editorial 

GREEN EFFICIENT TECHNOLOGIES 

Eric Schäfer 

editor-in-chief 

Accepting challenges 

Despite global crises and the resulting uncertainties, the mechanical 

engineering and toolmaking sector can look to the future with relative 

confidence at the beginning of 2023: the aviation industry is increasing 

the production of aircraft, and the energy sector is generating demand 

from the plant engineering sector. Wind power generators, heat pumps 

and plants related to the hydrogen economy, which is now increasingly 

coming into focus, including all the components required, are driving 

demand for tools. 

The American demand is increasing, China remains an important 

market, as do the East Asian markets, only the development in 

Europe is stagnating. 

However numerous challenges remain. In order to meet these in the 

future, machining as a production technology must strive for higher 

productivity and greater sustainability. For example, energy consumption 

in machining can be reduced by replacing peripheral processes such as 

wet lubrication with low-energy lubrication systems such as minimum 

quantity lubrication (MQL). 

MAXIMUM SAFETY. 

HIGH FLEXIBILITY. 

ROBUST DESIGN. 

MAXIMALE SICHERHEIT. 

HOHE FLEXIBILITÄT. 

ROBUSTES DESIGN. 

Hygienisch fördern 

WANGEN VarioTwin NG 

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

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PROZESSTECHNIK & KOMPONENTEN 

2022 

PROCESS TECHNOLOGY & COMPONENTS 

PROZESSTECHNIK & KOMPONENTEN 

The hygienic solution 

WANGEN VarioTwin NG 

PROCESS TECHNOLOGY & COMPONENTS 

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













2022 

2022 

2022 

Such a change, in conjunction with low-melting materials such as 

aluminum alloys, can lead to problems in terms of tool performance, 

tool life and process reliability. The authors of the Fraunhofer Institute 

for Manufacturing Engineering and Automation IPA and the University 

of Stuttgart report in a scientific study on how these can be solved and 

the potential of using biomimetic microstructures in this context. 

Examples in the user reports from the industry demonstrate how challenges 

in daily manufacturing processes can sometimes be overcome by the joint 

use of know-how from two partners. 

Eric Schäfer 


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System Integration and 

other alternative options 

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info@harnisch.com · www.harnisch.com

table of contents 

cover story 

Who the f*** is Adelbert? 

Interview with Dirk Wember, managing director Adelbert Haas GmbH 6 

materials & tools 

Kennametal expands modular drill portfolio 9 

Small, strong, robust – new centric vice makes a big difference 12 

Energy- and resource-efficient aluminum machining 

Supporting minimum quantity lubrication technology by biomimetic micro 

structures on 2D-orthogonal cutting tools generated with ultrashort laser pulses 14 

The revolution in tool handling 27 

LACH DIAMANT looks back on 100 years – 15 th part 

Diamond contra diamond? A reflection on the versatility of diamonds 28 

processes 

The “smallest” world sensation of 2023 38 

Machining graphite: reliably and unmanned 41 

Measurement solutions from a single source in transmission component manufacture 42 

machining center 

Appealing state-of-the-art technology 44 

Laser processing improves quality and tool life and secures competitive advantage 46 

Machining centers as “green” welding cells 47 

components 

Cutting tool measurement and compensation 

How measurement machines and software easily communicate 48 

news & facts 31 

fairs 50 

impressum & company finder 51 

4 no. 1, March 2023

Cool Micro 

micro milling 

THE WORLD’S SMALLEST ENDMILL 

WITH INTEGRATED COOLING 

Discover more!

cover story 

Who the f*** is Adelbert? 

Interview with Dirk Wember, managing director Adelbert Haas GmbH 

Renaming und rebranding at Haas: 

Haas Schleifmaschinen GmbH will be known as 

Adelbert Haas GmbH. Haas Schleifmaschinen looks 

back, forward and reflects on its pioneer and founder 

Adelbert Haas. 

Mr. Wember, the company name and the brand logo should 

actually be the last things to be changed. Both are, after all, 

the epitome of popularity, trust and, in addition, a value 

proposition in themselves. 

Dirk Wember: I completely agree with you on that. And yet 

there are important occasions to do so. That’s precisely why 

we didn’t go for extreme renaming and come up with some 

meaningless word creation. The need for a cautious brand 

evolution has become more and more imposing in recent 

years, and now we are boldly taking this step. I would like to 

explain the reasons for this, and perhaps one or two 

other machine manufacturer are also facing this challenge 

and can take us an example. 

We are still a bit surprised, because news from Trossingen 

are usually high-tech innovations. What were your reasons 

for taking this step? 

Dirk Wember: I’ll tell you the main reason that has been 

on my mind for years. We have long outgrown our previous 

name, Haas Schleifmaschinen. The name limits us ar too 

much and at some point in the near future slows down our 

business development instead of giving it a proper boost. 

We don’t build grinding machines, we develop unique 

technologies and are valued for our solution expertise. Our 

own software plays a decisive role in the requirements of 

the future. As a company we are a hybrid and unique in our 

industry. On the one hand, we are a machine manufacturer 

in the grinding segment, and on the other hand, we are a 

software pioneer with solutions that make us interesting 

outside our very specific industry. And when we reach 

limits at Haas, we want to overcome them as quickly 

as possible, currently with a new appearance and 

technologically anyway. 

Is there a specific example that illustrates this? 

Dirk Wember: One example among many – Styx! With 

our Multigrind® Styx software we visualize and optimize 

complete production processes before the workpiece to be 

ground is even clamped into the machine. This digital test 

bed for 3D optimization offers, with its 1:1 visualization, 

Mail from Trossingen: A new company name and a new logo, which remained almost completely the old one. 


cover story 

Since the beginning of 2000, Dirk Wember has been a shareholder and managing director of Adelbert Haas GmbH; 

he shares this task with his daughter Marie-Sophie Maier-Wember and with his long-time partner 

and chief technology officer Thomas Bader. 

maximum control, pixel-perfect and without restriction. 

This saves a lot of time and unnecessary grinding of 

expensive blanks. After all, it doesn’t take much imagination 

here to envision what this technology could do in related 

industries as well. 

Are there any further reasons or did they just want 

to get rid of the term grinding machines? 

Dirk Wember: A common reason for changing the brand 

name is also successful internationalization. This has also 

occurred in our case. We are advancing on all continents, 

and this naturally generates conflicts. For us, a unique 

position in the market is indispensable. We want to clearly 

define ourselves with our cutting-edge technology and 

generate even more interest in our solution offerings 

worldwide. To do this, we need to differentiate ourselves 

to avoid any possible confusion. With the new name 

Adelbert Haas GmbH we strengthen the brand protection 

internationally and still remain flexible for what we have 

planned for the future. 

And what does all this have to do with the 

founder, Adelbert? 

Dirk Wember: Well, if you have a plan A, you don’t need 

a plan B. A like Adelbert. With Adelbert we want to create 

an awareness of our origin from the Black Forest. Adelbert 

Haas turns origins into the future. We have always been 

innovators, pioneers and “won’t work, doesn’t exist” 

enablers. We are consistent, courageous and always close to 

the challenges of our customers. These characteristics have 

characterized us for almost 90 years and are an immutable 

part of our corporate DNA. That’s why the decision to go 

with Adelbert Haas GmbH just fell into our laps. 

Isn’t Adelbert Haas GmbH a bit too bulky, 

especially outside the language area? 

Dirk Wember: Yes, of course Adelbert is bulky, and that’s 

a good thing. A name with rough edges initially causes 

discussions, but pays off in the long run. We are not afraid 

of the tongue twister, we have become far too relevant in 

the market for that. It is precisely what is unusual about 

our Adelbert that makes it special, and we want to be 

special for our customer, too. The company has never 

lacked uncompromising courage, on the contrary. 

Who else in our industry would have named their new 

tool grinding machine Multigrind® Radical? We think 

radically differently, act in a future-oriented way and 

that is exactly what our customers appreciate. 

(Dirk Wember laughs and adds:) 

People certainly need some time to get used to the Adelbert. 

We are happy to take this time. Acceptance and identification 

are very important to us, both internal and external. Just 

imagine our loyal customers, the Haas brand means a lot to 

them. And suddenly they are presented with some fantasy 

name? Then you take away something they valued and 

trusted. We want to preserve our psychological added value, 

and with it our attitude and our aura. 

It is clear, however, that even if our motives are valid, they 

will of course be questioned by the public, and that is a 

good thing. Our new name has to measure up to the 

no. 1, March 2023 

7

cover story 

Image caption, 

social media example 

for the new 

Multigrind® Radical. 

previous one, so we didn’t want a blank slate. We have 

proceeded cautiously and yet courageously. With a 

completely new brand name, memories are lost, we 

avoided that with the decision to Adelbert Haas GmbH. 

But why now of all times, our readers will ask 

themselves. Are there any other reasons after all? 

Dirk Wember: I will formulate this in the exclusion 

procedure so that no misunderstandings arise: there is 

no outside investor at Adelbert Haas. We have not merged. 

We were also very successful during Corona and even used 

the time to develop our Multigrind® Radical. Our order 

books are full, and we are looking ahead with great 

confidence. Thomas Bader and I have added another 

managing director to the circle in the form of my daughter 

Marie-Sophie Maier-Wember, placing the growth themes 

of digitization and software at the very top. 

And if there are still unanswered questions, just call me, I 

am always happy about the direct contact, especially 

after the past two years. 

Can such a change of name go wrong? 

Don’t you have sleepless nights before it? 

Dirk Wember: Of course, there is no guarantee; ultimately, 

it is the public that decides on success or failure. I can well 

remember a negative example from past years, and honestly, 

it still hurts today. The name change from Michael Deckel 

to ISOG was a fiasco, both in terms of craftsmanship and 

psychology. All the brand capital that had been built up 

so successfully – everything that the customer associated 

with the brand – was lost. We know the result: 

shutdown in April 2020. 

Mr. Wember, renaming and rebranding is certainly 

expensive and requires a lot of marketing know-how. 

Why didn’t you shy away from it? At the end of the 

day, it’s always a cost-benefit calculation 

that has to work out, isn't it? 

Dirk Wember: The development of a global brand, with its 

strategic, legal and linguistic challenges, is a real challenge, 

and we were aware of that from the very beginning. But 

pioneering spirit never looks at the costs first, but has the 

result, the benefit as its goal. 

And on the subject of marketing, that has always been my 

hobbyhorse and I learned the tools from scratch. If we can’t 

communicate our topics, they won’t exist in the market. 

That’s why an offensive communication and marketing 

strategy is essential. In line with our attitude, we always 

have the best professionals at the start, also in marketing. 

And let me tell you, marketing is really fun, just take a look 

at our current campaign for the launch of the Multigrind® 

Radical. We get a lot of praise and our competitors maybe 

a gray hair or two. 

Mr. Wember thank you for sharing your thoughts 

and marketing concept with our readers. 

Dirk Wember: I have to thank you on behalf of Adelbert 

Haas GmbH and on behalf of all Haas employees. 

More efficiency and productivity – virtual process optimization with Multigrind® Styx. 

further information: www.multigrind.com 



Kennametal expands 

KenTIP TM FS modular 

drill portfolio 

Kennametal adds to its KenTIP TM FS modular drill 

platform by leveraging the patent-protected GOdrill TM 

technology for a new insert, the KenTIP FS GTP, along 

with several new straight-fluted drills for multiple materials 

and applications including the KenTIP FS SCF 

and KenTIP FS BF holders. 

➢ KenTIP FS GTP: using the 140-degree solid carbide point 

design from Kennametal’s GOdrillTM, the KenTIP FS GTP 

insert allows for multiple machining applications across a 

range of materials including steel, stainless steel and cast 

iron. KenTIP FS GTP also features excellent centering 

capabilities, even at moderate cutting parameters, and lowaxial 

forces. 

➢ KenTIP FS SCF Holders: the KenTIP FS SCF Holders 

feature a straight- fluted design for static applications on 

lathes. The SCF shank with flange allows for quick and easy 

usage on common lathe turrets. With this new addition 

to the KenTip FS portfolio, machinists can expect reliable 

chip evacuation and maximum torsion resistance, plus 

superb temperature control and lubrication because of an 

internal coolant supply with four exits. 

➢ KenTIP FS BF Holders: these straight-fluted drills for 

drilling, countersinking and chamfering (in one operation) 

a feature Weldon shank for standard BF adaptors. The 

straight flute design enables the length to be adjusted and 

delivers reliable chip evacuation and maximum torsion resistance. 

The KenTIP FS BF Holders deliver superb temperature 

control with internal coolant supply at four exits. 

further information: www.kennametal.com 

A strong signal in 

the field of special 

machining 

VARIOTEC 00P: FOR SPECIAL 

PERFORMANCE RESULTS 

■ Facilitates handling when fitting a new 

cutting edge 

■ Special design of the VARIOtec 00P tools 

prevents the inserts from twisting in use 

■ Optimised chip chambers ensure excellent 

chip evacuation 

■ Enabling high cutting data and high metal 

removal rates 

www.boehlerit.com


Precision trio inspires innovation together through successful partnership: 

Quality, reproducibility and 

delivery times guaranteed 

Experts from EXTRAMET, MPK and ZECHA 

The applications in which stamping and forming or 

embossing tools are required are manifold: for example 

the production of many everyday objects, such as 

components for electronic or household devices as well 

as the automotive industry, would not be economically 

possible without these tools. 

This is because they are usually intended for mass production, 

where they must deliver maximum performance every 

(milli) second and demonstrate a long service life. To meet 

these requirements, MPK Special Tools GmbH in Schwäbisch 

Gmünd manufactures high-quality active parts for stamping 

and forming with precision tools from ZECHA Hartmetall- 

Werkzeugfabrikation GmbH from extruded carbide from 

EXTRAMET AG with maximum technological diversity. 

Together, the three long-standing partner companies break 

new ground every day. 

“Especially customer requests that differ from the standard 

pose major challenges with regard to surface quality, service 

life, and reproducibility, which we are happy to take on. 

Our goal is to work together with the customer to implement 

solutions for its specific applications with the smallest tolerances 

and exacting manufacturing tasks in the best carbide,” 

explains Arndt Fielen, sales manager at MPK Special Tools. 

Thanks to the certified raw materials from EXTRAMET, the 

μ-precise tools from ZECHA and the combined know-how of 

the three experts, MPK Special Tools offers customers security 

from project conception to final application and analyzes, 

develops and manufactures the ideal solution based on customer 

drawings using a wide range of technology combinations 

in milling, grinding and eroding. 

For more than 40 years EXTRAMET AG has been concentrating 

continuously on its core competence: the production 



of high-quality carbide. In doing so, it relies on innovation, precision and high 

technology. The product range, like the entire company, has constantly evolved. 

In the past solid carbide rods were mainly manufactured for the tool industry, 

but today EXTRAMET offers its customers and partners, in addition to a comprehensive 

product range, primarily tailor-made solutions for their individual 

needs. 

As a solution partner for the high-tech industry, the carbide specialist supports 

its customers in optimizing production processes and saving manufacturing 

costs. Highest precision, coupled with carbide in top quality, makes the 

independent family business the ideal partner for companies that also place the 

highest demands on their product. Quality and reliability represent a principal 

component of the corporate philosophy. Because only through consistent and 

uniform quality of the carbide blank can process-stable tools be produced, that 

offer a high level of safety for the end customer in use. 

MPK Special Tools GmbH has been an expert in precision technology for 

over 60 years. Manufactured according to customer drawings, the holistic 

tool and complete solutions made of carbide and steel are characterized by the 

highest precision in any quantity. Stringent quality controls as well as unwavering 

adherence to deadlines and deliveries are essential for the success of 

customers, especially in sensitive industries. The services for the purchase of a 

tool from MPK Special Tools include on-site presence, direct exchange with the 

customer at the machine, and the resulting consulting and service – versatile, 

accurate and individualized. 

Your 

Precision 

Motion 

Made Easy 

ZECHA Hartmetall-Werkzeugfabrikation GmbH is among the pioneers 

and trendsetters in the field of micro cutting, blanking and forming tools. The 

company’s origins in the chronograph industry can be seen not only in its uncompromising 

specialization in the production of miniature tools of highest 

precision, but also in its sophisticated special tool solutions. Precision and quality 

are the key for the international employment in different industries, such 

as medical and dental technology, the chronograph industry, the automotive 

industry or in tool and mold making. Experts in the company’s own research 

and development department are constantly developing groundbreaking geometries 

and tools for sophisticated applications and innovative materials. 

In addition, tool reproducibility is also guaranteed even for years on account 

of the life number stamped at the end of the shaft of every tool. Modern CNC 

machines, high-end measuring and testing technologies and carefully selected 

carbides from leading manufacturers, as well as intensive cooperation with 

their customers and partners, ensure the exceptional perfection of their tools. 

Thanks to decades of joint experience and cooperation EXTRAMET, MPK 

Special Tools and ZECHA ensure excellent results in stamping and forming 

technology. Maximum process reliability, increased service life, and surface 

quality while simultaneously reducing production costs are (thus) guaranteed. 

The close partnership makes it possible to meet individual customer requirements 

quickly and flexibly, because the smooth interaction of the individual 

components is decisive for success. 

The individual areas from prototype to series production are optimally 

coordinated through direct communication between the specialists at 

EXTRAMET, MPK Special Tools and ZECHA. The three companies continue 

to combine their expertise in order to develop reliable solutions for their customers 

through internal investments and expansions. The matching of carbide 

grades and geometries to a wide variety of applications, new manufacturing 

processes, and materials to be machined will continue to have top priority 

in the future. 

further information: www.zecha.de 

FIND YOUR 

SOLUTION


Small, strong, robust – 

new centric vice makes a big difference 

Successful sub-contract machining providers 

need to be flexible and respond quickly to customer 

requests. SIBA Metallverarbeitungs GmbH, based in 

Dillenburg, Germany, maximises its potential through 

innovative use of tooling and workholding, including 

clamping systems of all sizes from CERATIZIT. 

With the new ZSG mini centric vice, the company is now 

expanding its clamping range to include smaller workpieces. 

Small, robust and extremely strong: the ZSG mini from the 

WNT Performance range from CERATIZIT is expanding the 

range of clamping devices at SIBA Metallverarbeitungs GmbH 

A specialist in steel and aluminum machining, SIBA 

Metallverarbeitungs GmbH works with countless customers 

from sectors such as mechanical engineering, electrical engineering, 

the food industry, furniture-making and control 

cabinet construction. Founded in 1962 by Siegfried Bastian 

and currently in its third generation of family management, 

the company has more than 60 employees working in production 

and management now. 

Short response times for satisfied customers 

SIBA is geared towards maximum diversity, as Benjamin 

Herbert, machining production manager, explains: “Our 

portfolio includes sophisticated welded assemblies and we 

draw on a wide range of sheet metal processing methods 

including laser cutting, punching and bending. We also have 

capability for accepting and storing blanket orders and processing 

these on request as well has planning work from A to 

Z – right through to final assembly. If someone needs a single 

part we can help with that too – quickly and efficiently.” 

This is the ideal place to put the ZSG mini to work 

That versatility and flexibility is one of the company’s 

greatest strengths, not everyone can or will offer speedy 

response times, where the customer gets the required part 

within 24 or 48 hours. Vital to keeping its promises are its 

manufacturing efficiencies: 

Excellent cooperation: Lukas Faak (left), 

technical consulting & sales Cutting Tools at CERATIZIT and 

Benjamin Herbert, machining production manager at SIBA 

SIBA customers can often get their ordered parts 

between 24 to 48 hours 



technical consulting & sales Cutting Tools at CERATIZIT. 

Once in place the jaws are totally secure in the base body 

thanks to the integrated pull-down action generated by two 

spring pressure pins, that ensure total machining precision and 

quality. “I can insert and clamp the part during initial clamping, 

and the jaws hold the workpieces securely in place – without 

any additional pre-stamping. And I can start cutting, including 

ambitious milling processes, without worrying about 

anything,” says Benjamin Herbert. Adding to the robust nature 

of the vices, the base body is also made from hardened stainless 

steel, which makes it resistant to external influences. 

In terms of handling, the ZSG mini is a godsend for 

SIBA Metallverarbeitungs GmbH; after all, it’s a matter 

of seconds before the centric vice is ready to use 

thanks to the indexable grip jaws 

“In order to deliver at this speed, we need clamping 

devices of all shapes and sizes in our machining department. 

We’ve been working successfully with CERATIZIT 

for some time now to make this happen. And, for us, 

the new ZSG mini has completed the range by including 

smaller components,” explains Benjamin Herbert. 

Simple design, uncompromising functionality 

When the small centric vice was first presented, 

Benjamin Herbert and his machining team at SIBA put 

it straight to work, and quickly saw the benefits of this 

new workholding system. “In terms of its design the 

ZSG mini is actually very simple but uncompromising 

when it comes to its functionality. The various aspects 

that were taken into consideration in its design were 

definitely to our advantage: pull-down action, repeatability 

– it was perfect for us,” adds Benjamin Herbert. 

Holistic, not one-sided 

“What makes working with CERATIZIT so special is the fact 

that from the outset they’ve been very involved in our processes. 

In other words they’ve been proactive in trying to understand 

our needs and have always gone above and beyond: 

with tools, materials and ideas. This has resulted in an excellent 

collaboration over the past six years,” stresses Benjamin 

Herbert. 

In addition to clamping devices, SIBA also successfully 

uses adapters and tools from CERATIZIT. “The increasing 

challenges in the market today mean we need to be flexible and 

react quickly. That’s why we’ve also decided to use the ToolO- 

Mat from CERATIZIT. Here, we can store tools, use them flexibly 

and keep them available at any time – regardless of delivery 

times or supply chains!” 

PRECISE. POWERFUL. PRODUCTIVE. 

kapp-niles.com 

further information: www.ceratizit.com 

Short changeover times thanks to easy handling 

Rapid and easy handling is often the key factor in the 

race to reduce non-productive time to a minimum. The 

ZSG mini scores here highly too, as Benjamin Herbert 

confirms: “The ZSG mini is actually very nice to use, especially 

because of its excellent accessibility. The advantages 

of the ZSG mini become clear particularly when 

large pallets need to be equipped or where situations 

involving difficult-to-reach areas such as clamping towers 

or multiaxial processing need to be tackled. It can 

be mounted very quickly from one side and doesn’t need 

to be screwed underneath!” 

“But what saves an enormous amount of time is the 

quick change system for the jaws. They can be replaced in 

a matter of seconds without any tools at all by extracting 

them at an angle through the center,” explains Lukas Faak,


Energy- and resource-efficient aluminum machining – 

Supporting minimum quantity lubrication technology by biomimetic micro 

structures on 2D-orthogonal cutting tools generated with ultrashort laser pulses 

written by 

P. Esch, O. Schwarz, K. Placzek, D. Holder, R. Weber, 

M. Steck, F. Hartmann, Prof. Thomas Graf 

Fraunhofer Institute for Manufacturing Engineering and Automation IPA 

University of Stuttgart 

1. Introduction 

Machining is a widely used production technique. Latest 

ecological and economical aspects cause a shift in machining 

production towards higher productivity and more sustainability. 

In order to reduce the amount of energy used in 

machining, peripheral processes like wet lubrication may be 

substituted with low energetic lubrication systems like minimum 

quantity lubrication (MQL). This change in combination 

with low-melting work piece materials like aluminum 

alloys creates problems in terms of tool performance, tool 

longevity and process reliability. 

In order to further enhance MQL production technology 

at least on the performance level of conventional cutting, this 

research study investigates the effects of micro structuring 

cutting tools rake faces by laser ablation. Functional bio-inspired 

micro structures (biomimetic structures) are selected 

and evaluated in 2D-orthogonal cutting and under static 

conditions. The effects on the functional features during capturing, 

transporting and releasing of the employed MQL-oil 

is getting analyzed. The goal is to evaluate and quantify the 

potential of feasible biomimetic structure variants. 

(cf. Martin 2013 [1] ) 

2. Micro structures 

2.1 Micro structures in machining 

Micro structured tools are recent subject of scientific research 

in order to optimize machining tools. In Chang (2011) [2] 

micro structured milling tools are investigated on NAK80 

steel. The structured tools outperformed the standard milling 

tool exhibiting lower cutting forces and higher longevity, 

indicating best results with a 90 ° orientation of micro structure 

cavities in relation to the cutting edge. Comparable results 

are reported in Schneider & Esch (2017) [3] in the application 

of drilling. Likewise, perpendicular structures showed 

best results in reducing force response and wear behaviour. 

Özel et al. (2021) [4] gives a comprehensive review on the state 

of the art in tool face functionalization by micro structuring. 

The general consensus of superior machining performance 

is accompanied by the indication of a shortage in scientific 

research in terms of bio-inspired approaches. In this context 

and without any claim to comprehensiveness only three 

relevant scientific contributions could be found. Tillmann et 

al. (2015) [5] studies the feasibility and effectiveness of bio-inspired 

structures on friction coefficient. Fatima & Mativenga 

(2017) [6] transfers the biomimetic structural approach into 

the machining application by investigating the effect of a 

replicated ball python skin structure in turning AISI4140 

steel. The structured tools show superior performance in 

terms of lower cutting temperature, reduced cutting forces 

and higher chip compactness. Aside biomimetic structures 

on a micro scale, Schmidt (2021) [7] developed macro tooth 

geometries for wood working application. 

In summary, biomimetic structures are yet to be scientifically 

addressed and investigated. It is also crucial to understand 

the effective mechanisms of biomimetic structures and 

its practical implementation. 

2.2 Generation of surface structures in the 

micrometer range by surface structuring 

with ultra-short laser pulses 

By means of ultra-short pulse laser ablation, it is possible to 

generate specific laser-induced structures (LIPSS) on the surface 

of the component (cf. Bonse et al. 2018 [8] ). By selecting 

different process parameters, different LIPSS, such as ripples, 

grooves and spikes can be generated (figure 1). These 

structures exhibit different morphological properties such 

as structural composition and roughness. In addition, the 

structures differ in wettability with water and other liquids 

and could function as wetting structures near the cutting 

edge to support lubrication. (cf. Kietzig et al. 2009 [9] ) 

In Holder et al. (2021) [10] the use of ultrashort laser pulses 

for micro machining grooves for passive fluid transport on 

Ti-6Al-4V surfaces is demonstrated. This work shows the potential 

of using ultrashort laser pulses for micro machining 

of cavities for lubrication transport. (figure 1) 

3. Research 

The declared goal of this study is to investigate and prove 

the feasibility and effectiveness of laser fabricated biomimetic 

micro structures in the machining application. The chosen 



a) ripples b) grooves c) spikes 

figure 1 

SEM images of LIPSS-structures on 100Cr6 steel 

approach focuses on micro patterns functionalizing the tools faces in order 

to improve the effectiveness of deployed lubrication and help to prevent oilstarvation 

by reserving oil in the cavities. This second research approach will 

be addressed in an follow-up investigation based on the given results in this 

study. 

3.1 Methodology 

The chosen methodology comprises a profound research of applicable and 

relevant micro structures which fulfil the necessary functions. As stated before, 

the micro structures shall comply with two functionalities: a) transport 

given lubrication underneath the sliding chip and b) to release the lubrication 

at a spot near the cutting edge for higher lubrication effectiveness. 

In a biomimetic approach possible structures with similar functionalities 

to the technically required ones are identified. A selection of suitable 

structural patterns is carried out, reducing the possible range of patterns to a 

technological feasible choice. 

The selected patterns are abstracted and transferred into CAD models, 

which then can be produced with laser technology. The realised biomi metic 

structure variants are then tested in a 2D-orthogonal test stand. (figure 2) 

3.2 The Biomimetic approach to suitable structures for machining 

The aim of biomimetics is to solve technical problems by abstracting, transferring 

and applying knowledge gained from biological models. Its application 

in the product development process as 

an innovation method enables innovative 

technical solutions. With regard to resource 

efficiency, biomimetics offers considerable 

potential because one of the most important 

selection features in evolution was the saving 

of energy and material. It is assumed that 

so-called ecological management is possible 

through the transfer of biological models 

and principles to technol ogy. The functions 

and properties developed in the course of 

evolution are thus “ecologically” optimised. 

However, it must be taken into account 

that this optimisation has always taken place 

with regard to the multiple influencing variables 

of the environment and the optimisation 

of the overall performance, i.e. ensuring 

the survival of an organism. The maximisation 

of one function dissolved of the context 

has rarely been in the foreground. I.e. if the 

technical problem finds possible solutions in 

nature, then the overall context and boundary 

conditions in which it functions must be 

considered. In any case, there is almost always 

the potential for this function to become even 

more effective through human or technical 

modification, because no consideration has to 

be given to other life functions. In this in application-oriented 

work we have a top-down 

problem, i.e. there is a technical problem for 

which a solution is to be developed. (figure 2) 

The formulation of the technical problem is: 

“MQL reaches the cutting edge to an insufficient 

extent” (in order to reduce friction there 

and thus heat generation). The transfer of the 

problem leads via an abstraction: “How can 

a fluid reach defined locations over greater 

distances”. 

figure 2 

Procedure diagram in the search for biomimetic solutions 

The statement must be narrowed down and 

made more precise in order to expand the 


15


search space in nature accordingly: the specification of the fluid’s behaviour 

leads in principle to either hydrophilic or hydrophobic fluids. In nature, both 

properties are present – there are oily fluids and, of course, in the majority of 

cases water-based fluids. 

On the part of the tool geometry, the requirement is that the coolant must 

overcome a greater distance, i.e. several millimeters to a few centimeters and 

not just in the range of micrometers. Defined locations were understood to 

mean that the fluid is not guided randomly, but over predefined structures. 

In principle, a distinction must be made between transport structures and 

two-dimensional wetting structures. 

The search field for biomimetic structures is now defined and could thus 

be expanded. A range of wetting and transport systems could be found as 

described below. 

Queries were made in various scientific databases and in the patent database 

Depatis-net. The search included terms such as “water collection” and 

“transport”, “unidirectional” and “directional liquid transport”, “capillary 

effect”, “hydrophilic and (super) hydrophobic structures”, “wetting” and 

“moistening”, “edge angle” and as nouns or verbs in various combinations 

with and without the term “biomimetics” or “bionics”. 

On the one hand descriptive biological publications (basic research), on 

the other hand publications on the experimental biomimetic imitation of 

found principles as well as abstracted technical structures already described 

in patents were found. 

The main four principles on which the specific and unspecific conduction 

of water, oil or other liquids is based are the following: capillary effect, alternating 

hydrophilic and hydrophobic regions, hierarchical micro structuring 

and specific rough surfaces. 

3.3 Experimental setup 

In order to evaluate the isolated effect of micro 

structures on process performance, complex 

milling tools are transformed into simple 

2D orthogonal cutting tools. The given geometrical 

circumstances are translated into 

a 2D cutting tool with plane faces according 

to the methodology also stated in Esch et 

al. (2021) [11] . Plane rake faces are easily workable 

and geometrical influences are excluded. 

Figure 3 shows a tool derived from a standard 

aluminum cutting tool. 

The tool specifications are given in table 1. 

The workpiece material was AlMg4,5Mn0,7 

(EN-AW 5083). According to Ostermann 

(2014) [12] its main applications are rail vehicle 

construction and general construction due to 

the advantageous characteristics in ductility, 

corrosion resistance and fusibility. The workpiece 

was prepared in a sliced blank with defined 

towering bars the size of 5 x 10 x 250 mm 

in the dimensions width, height and length. 

specimen 

force 

dynamometer 

figure 4 

Specimen with towering bars for 2D cutting 

rake 

angle / ° 

wedge 

angle / ° 

figure 3 

2D cutting tools with plane rake face 

clear 

angle / ° 

grain 

size / µm 

ISOclassification 

cobalt / % 

tungsten 

carbide / % 

10 ° 78 2 0,65 K30 10 90 

table 1 

Tool specifications 

Experiments were carried out on a DMG HSC 

70 linear. The transverse axis was used to perform 

the cutting motion with a maximum 

speed of 80 m/min. A specially designed tool 

holder held the tools in front of the spindle 

housing. The full experimental setup is given 

in figure 5, also showing the chip formation. 

The tool was guided over the bars with a cutting 

speed of 80 m/min. Every tool executed 

15 runs on a new bar strip with a defined 

infeed of 200 μm for each run. The deployed 

lubricant was a FUCHS ECOCUT MICRO 

PLUS 20. Lubrication supply was realized by 

jet nozzle and micro dosage. 

Force transformation was conducted according 

to the model of Ernst and Merchant (cf. 

Ernst & Merchant 1941 [13] ). The recorded force 

response in cutting and normal cutting direction 

could be translated into the effective 

friction and normal forces acting on the 



cutting direction 

external MYL jet nozzle 

Y 

Z 

X 

coordinate system 

measuring device 

figure 5 

Experimental 

setup in machine 

tool center 

figure 6 

Force translation 

model according to 

Ernst & Merchant 

(1941) [13] 

rake face. The ratio of normal to friction force also allows the 

derivation of the relevant friction coefficient γ. Figure 6 depicts 

the force vector transformation model 

4. Micro structures of biological models 

and their selection 

The following animal and plant species have been identified 

as having potentially suitable transport or wetting properties: 

In arid regions, water is a precious commodity that should be 

absorbed as quantitatively as possible and not only from rain, 

fog or stagnant water, but also moist soil. A group of lizards, 

including the Australian thorny devil (Moloch horridus), the 

Texas toad (Phrynosoma cornutum) or the Arabian toadhead 

dragon (Phrynocephalus arabicus) have developed special 

characteristics: moisture spreads excellently on the skin (contact 

angle ≤ 10 °) because it is super hydrophilic due to a honeycomb-like 

micro structuring. The capillaries are very fine 

– approx. 10 to 30 μm wide and 1 - 5 μm deep. This enables 

them to collect water. 

In these three species, there is also conduction to the mouth 

via a capillary structure formed by partially overlapping 

scales, forming a semitubular capillary system over the entire 

body of the lizard, with a basal width of 100 to 250 μm and a 

narrower opening (cf. Comanns, 2016 [14] ). 

Water collection and transport is passive, i.e. without any 

actively supporting movements. 

Transport velocities on the integument of Australian thorny 

devil for example were determined for vertical orientation; on 

the ventral body surface, transport was 5.8 cm within 5 min. 

The maximum height was 9.9 cm. However, Texas toad, in 

contrast to the other two, exhibits a significant directionality 

towards the mouth, a directional transport. In the abstracted 

conversions of Comanns (2016) [14] , Comanns (2011) [15] , 

Comanns [16] , Joel et al. (2017) [17] , Kim et al. (2019) [18] ) in epoxy 

resin in the ratio 6:1 could be verified in observation and 

reproduced even more clearly than in the biological model. 

The derived technical transport structures were patented by 

Comanns et al. [19] . 

While the lizards can also draw from many sources – such 

as moisture from sands, the Namib desert beetle (Onymacris 

unguicularis) relies exclusively on nocturnal fog as a water 

source. Grooves on the wing covers allow the condensed dew 

droplets to collect due to hydrophilic and hydrophobic surface 

properties and then flow to the mouth following gravity. 

In a number of closely related species, its surface grooves 

proved to be particularly effective. The reason is alternating 

hydrophobic (wax-coated) and hydrophilic (non-waxy) 

regions as well as Gibbs free energy. (cf. Tan et al 2016 [20] , 

Hirai et al. 2017 [21] ) 

The shipyard cockroach (Ligia exotica) has structures that exhibit 

low surface energy and allow directional wettability of 

an entire leg. They are thought to be important for the development 

of a robust water transport and passive water uptake 

system without external energy consumption (cf. Kim et al 

2019 [18] , Kirner et al. 2017 [22] , Ishii et al. 2013 [23] ). 


17


An unidirectional transport mechanism has been developed 

in the spermathecae of fleas, to ensure that the seminal fluid 

can also meet the egg cell. It can be assumed that such a function 

revolution is highly optimized because it directly affects 

the success of reproduction. The capillaries with extensions 

(reservoirs) and stops in the opposite direction cause transport 

in only one direction, that of the egg cell. The process, 

described by Buchberg as “fluidic diode”, was also technically 

abstracted by him and could be reproduced from PMMA 

fabri cated by laser-ablation (cf. Buchberger 2018 [24] ). Bark 

bugs (Dysodius lunatus) can become darker in colour due to 

water wetting of the elythras, which reduces the likelihood 

of being detected by predators sitting on the bark of the tree 

when the tree trunk also becomes more colourful and darker 

in colour when moisture is absorbed. 

In addition, plant bugs are also known for their smell. This 

presumably serves as a defence against enemies and is therefore 

optimised for rapid release. The underlying rapid mechanism 

is based on the directional spread of the scent secretion 

from the glands to the wing bases (cf. Kim et al 2019 [19] , Hischen 

et al. 2018 [25] , Blow et al 2009 [26] ). The spreading is effected by 

nub-like structures. With regard to the intended technical 

application, it is interesting that this is suitable for oily fluids. 

Springtails Collembola (Collembola spec.) are a group of inconspicuous 

ground-dwelling wingless insects, the so-called 

primordial insects. In contrast to the tracheal respiration of 

insects, springtails breathe through their skin. This characteristic 

causes the springtails to adapt in a very special way, 

because for undisturbed breathing the skin of the springtails 

must remain dry and clean at all times – and this in a 

habitat with plenty of water and dirt. A very perplexing surface 

coating has been discovered on them, which is omniphobic. 

These not only let the medium water and dirt roll off – as 

with the lotus effect – but also oily liquids. The skin structure 

of springtails, which is honeycomb-like and shows mushroom-shaped 

overhangs in cross-section, could be imitated 

by the Leibniz Institute of Polymer Research Dresden with 

polymer membranes. (cf. Nickerl et al. 2014 [27] , Hensel et al. 

2013 [28] , Gundersen & Leinaas 2014 [29] ) 

When asked why honey bees (Apis mellifera) themselves do 

not stick to their mouthparts with propolis when harvesting 

and processing propolis, Saccardi et. al. (2022) [30] discovered 

scale or honeycomb-like structures on the mandibles. They 

assumed a wetting structure. The structures were transferred 

to technical materials. It was shown that the surface pattern 

has no direct influence on propolis adhesion. However, it 

could be shown that a liquid film covering these structures 

and held by the hexagonal walls prevents adhesion. 

Superficial water-conducting structures are also known in 

plants. 

The fine spines of Opuntia microdasys apparently have the 

function of collecting fog or dew and directing the dew droplets 

to the surface of the cactus, where they roll off to the 

ground and can ultimately be absorbed by the root system. 

On the surface of the needle there are harpoon-like basally 

directed outgrowths. Ju et al. (2012) [31] due to the conical 

shape (Laplace pressure) and the surface-free energy gradient 

as a result of the surface becoming rougher and more hydrophobic 

apically (lower free energy), the fluid transport is unidirectional. 

The pitcher plants Sarracenia spec. and Nepenthes alata are 

insect-attracting plants, in order to let them slide down their 

smooth funnels and digest them inside. On the border of the 

pitcher or tube are hairs called peristomes, which have hierarchical 

micro channels arranged on the surface that, together 

with the Laplace pressures, cause water to be transported. The 

peristomes can be completely wetted by water and then form 

a slippery liquid film at the bottom of the can or tube on 

which insects start to slide. The formation of the liquid film is 

caused by a continuous transport of water from the inner to 

the outer border of the pitcher on the peristome. (cf. Chen et 

al. 2017 [32] , Zhang et al. 2017 [33] , Zhang et al. 2020 [34] ) 

Findings exist on this, which has verified the function using 

planar technical replicas in a two-step UV lithography 

with poly (dimethylsiloxane) (PDMS). Zhang et al. (2017, 

2020) [33, 34] concluded that these micro channels are ultrafast 

water harvesting and transport structures. 

In Sarracenia, the hierarchical structures as shown in figure 

7 a) consist of usually five grooves separated by four smaller 

marginal boundaries (second-order micro grooves), which 

are flanked at the outer edge by a high marginal boundary 

(first-order micro grooves). (cf. Chen et al. 2018 [35] 

The structure of Nepenthes is more complex. It also has firstorder 

micro grooves with about ten second-order grooves in 

between, there are many anisotropic, overlapping and arcshaped 

microcavities along the second-order micro grooves, 

with the tips of the arcs pointing towards the outside of the 

pitcher border. The interplay of microcavities and sharp arcuate 

edge (about 2 - 8 °) and inclined wedge angles on both 

sides of the microcavities (about 90 ° at the bottom of the microcavity, 

to about 28 ° at the top) prevent backward water 

transport and cause rapid unidirectional water conduction. 

(cf. Zhang et al. 2017 [33] ) 

4.1 Selection criteria for conversion to metal by laser 

The selection of potentially suitable transport and wetting 

structures was interdisciplinary. On the one hand the modifiability 

of the biological structures to circumvent the restrictions 

imposed by the laser processing of metal were considered. 

Secondly the robustness of principles under the technical 

application conditions and thirdly, the experimental 

results so far available in the literature were used for evaluation. 

The following biological examples were prioritised for 

technical realization: 

As transport structures the tube plant (Sarracenia spec.), 

the bark bug (Dysodius lunatus) and the toad lizard (Phrynosoma 

cornutum). (figure 7 c, d) 

As wetting structures the bark bug (Dysodius lunatus) and 

various cauliflower-like coarse structures, prisms, truncated 

cone-shaped pyramids and perforated plate-like depressions 

at regular intervals. 



a) hose plant 

b) spermatheca 

of fleas, 

in grey box is a 

«elementary cell» 

c) toad lizard (Phrynosoma cornutum), «elementary cell» 

figure 7 

Transport structures 

figure 8 

Wetting structures 

a) prisms 

c) truncated cone-shaped pyramids (also used as transport stucture!), 

inspired by Dysodius lunatus 

flow 

b) shell 

d) tilted steps structure 

As far as the nub-like structures are concerned, the 

distances of < 25 μm between them could not be realised with 

the currently available beam shaping. But the large number 

of conceivable variants of nap structures – in shape and 

spacing – that are comparatively easy to produce, as well as 

the facts that they are used to distribute oily liquids and that 

some have also been described in patents for wetting applications 

(cf. Comanns et al. [19] ), led to the decision to realise 

them later until the appropriate optical system is available. 

The honeycomb-like wetting structure is particularly interesting 

for solving the technical problem of effective MQL 

transport, but was initially set aside as reserve. 

Discarded were the structures of the Namib desert beetle. 

The problem seems that the transport properties are created 

by the complex interaction of hydrophobic and hydrophilic 

topographies, which cannot be realised by laser ablation, or 

only to some extent. 

Since the structures of the throwing cockroach tend to be 

hair-shaped protrusions, the technical feasibility of morphologies 

with unfavourable length-to-width ratios is difficult 

with lasers in metal. The technical implementation of the abstracted 

transport structure of the fleas’ spermathecae with 

laser in metal was refrained from because the complex windings 

are rather unsuitable for laser ablation. (figure 7 b) 

The omniphobic surface structures of Collembola are unfortunately 

not possible for ablation with laser, because of the 

overhangs or undercuts. 

The mechanism of Opuntia spines is closely related to their 

cylindrical shape. This bears little resemblance to the flat 

topographies on the tool and is therefore not transferred. 

The comparatively simpler channel structures of Sarracenia 

were preferred to those of Nepenthes, because they would 

require rectangular or acute angles and inclined surfaces that 

cannot be realised with the circular focal beam. 

(figure 7/8) 

5. Abstraction and transfer into CAD constructions 

In the abstraction step, which comes after the recognition of 

the principle as shown in figure 7, an attempt is made to implement 

the idea in technical material in a way that is suitable 

for production while retaining the functionality. 

The question is to what extent all angles and inclinations, 

curves and corners have to be transferred. Some morphological 

conditions can be logically explained by physical laws. 

Others, however, are still hidden. The potential and strength 

of biomimetics is such to be discovered by means of functioning 

models. 


19


A practical approach is to first stay very close to the model and then to simplify 

it step by step. Since some structural elements cannot be realised with 

the defined manufacturing process, or their realisation is only possible with 

an uneconomical use of time and energy, compromises have to be made and 

simplifications chosen right at the beginning. Also, for reasons of time and 

capacity, only a manageable number of variants are possible. Therefore subjective 

selection plays a greater role than one would like. 

6. Implementation of the structures 

6.1 Experimental setup 

The ultrafast laser system Duetto from Time-Bandwidth, which emits laser 

pulses with a wavelength of 1064 nm and a pulse duration of 10 ps was used 

for the experiments. The laser beam had a Gaussian intensity distribution, 

was circularly polarized by a quarter waveplate, and had a beam quality factor 

of M² < 1.3. The beam was positioned and scanned over the sample surface 

with a Galvanometer-scanner and focused by an F-Theta lens with a focal 

length of 80 mm. The resulting focus diameter was d 0 = 30±2 μm. For all 

experiments the focus of the beam was set on the surface of the sample. 

(figure 9) 

The cross sections of the biomimetic transport structures are shown schematically 

in figure 11. They can be realized by ablating with a certain number 

of parallel lines N l with the hatch distance 

a h and by using a certain number of scans 

N s over the surface. The number of parallel 

lines and the hatch distance define the resulting 

width a w of the cavity and the depth 

z c of the cavity can be adjusted by the number 

of scans N s (figure 11 a). By reducing the number 

of parallel lines with increasing number of 

scans, cavities with trapezoidal and V-shaped 

cross-sections can be realized (figure 11 b). 

This way, complex cavities with sub cavities as 

shown in figure 11 c) as well as the biomimetic 

structure with pyramids (B2.2) can be generated, 

too. As laser micro machined grooves 

typically exhibit a V-shape in the cross section 

(cf. Comanns et al. 2007 [19] , Zhao et al. 2019 [36] ) 

no ideal vertical walls of a capillary can be 

created. Therefore, generating cavities with a 

defined width by using a certain number of 

parallel lines N l leads to a trapezoid shape in 

the cross section (figure 11 d). As the depth 

of the cavity increases, it eventually forms a 

V-shaped cross section. 

figure 9 

Experimental setup for laser processing 

6.2 Implementation strategy 

The laser induced surface structures were generated by scanning the laser 

beam over the sample surface using a line by line strategy (figure 10). The 

pulse overlaps of the pulses in x-direction and in y-direction is adjusted by 

varying the scan velocity v s (while keeping the repetition rate of the pulses 

constant) and the hatch distance a h respectively. By varying the scan velo city 

and therefore the pulse overlap in the scanning direction, different surface 

structures were generated while keeping the repetition rate f rep = 500 kHz, the 

pulse energy E p = 21,5 μJ and the hatch distance a h = 6 μm constant. By scanning 

with scan velocities of v s = {3747; 1500; 300; 60} mm/s different wetting 

structures B1.1, B1.2, B1.3 and B1.4 were generated. (figure 13) 

figure 10 

Schematic illustration of ultra short pulse laser ablation 

figure 11 

Ideal cross section of the transport structures 

(a) – c)) and schematic representation of 

cavity formation during 

laser micro machining 

Complex 2D-structures such as the pattern 

inspired by bark bugs (E1 and E2) can be implemented 

by reproducing elementary cells in 

a CAD program and exporting the file as .dxf. 

The file can be imported into the scanner program 

and can be hatched using fill parameters 

(e.g. line hatching distance a h ). Enclosed 

elements (colored black in figure 12) are not 

scanned with the laser beam and are not ablated. 

(figure 12) 

The surface structures shown in figure 13 were 

generated using the implementation strategies 

described above: the LIPSS B1.1 – B1.4, the 

biomimetic structures B2.1 – B2.3, the simple 

transport structures T1.1 – T1.4, complex 

structures T2.1 – 2.4, and bug structures E1 

and E2. As the transport structures only vary 

in depth only representative images are shown 

in figure 13. 



The camera-based contact angle measuring device is shown in figure 14 on 

the left. A droplet with a volume of 1 μL of the fluid is placed on the structured 

surface using the dosing unit. The contact angle measurement is recorded 

from the time of droplet placement until 15 seconds after droplet 

placement, in order to analyze the contact angle as a function of the time 

after droplet placement. After the measurement, the sample was cleaned with 

acetone in an ultrasonic bath. The measuring fluid was the ECO CUT AL, a 

conventional lubricant from Fuchs based on a fatty alcohol. The functionalfigure 

12 

Implementation of complex 2D-structures 

LIPSS-structures B1.1 - B1.4 

bug structures 

E1 - E2 

Biomimetic structures B2.1 - B2.3 

figure 13 

Generated surface structures 

simple transport structures 

T1.1 - T1.4 

complex structures 

T2.1 - T2.4 

figure 14 

Schematic illustration of the setup 

for contact angle measurements 

and flow velocity measurements 

7. Evaluation of the structures under static conditions 

7.1 Methods 

Contact angle measurements and flow velocity measurements were performed 

in order to evaluate the functionality of the wetting structures and 

the transport structures, respectively. 

ity of the generated transport structures was 

evaluated by means of measurements of the 

flow velocity. The setup for these measurements 

is shown in figure 14 on the right. The 

pipette was used to deposit 5 μL of the measurement 

fluid at the inlet port. The flow of 

the fluid from the inlet port via the different 

transport structures to the target port is recorded 

by a camera. With the help of image 

analysis programs, the flow velocity of the 

individual transport structures can be determined. 


21


7.2 Wettability of the biomimetic structures 

Structuring surfaces with ultrashort laser pulses can lead to a time-dependent 

change in wetting properties (cf. Kietzig et al. 2009 [19] ). Therefore the 

contact angle considered for evaluation in this chapter is the contact angle 

of the liquid drops on the surface structures after aging. The aging of the 

sample surfaces was reached after 30 days, as the value of the measured contact 

angle remained constant after this point of time. Figure 15 shows the 

contact angle determined for lubricant droplets on the aged sample as a 

function of time after droplet placement on the structure. For reference, the 

change of the contact angle over time after droplet placement was also determined 

for an unstructured polished sample (reference, red). Structures that 

did not have a lower contact angle than the reference contact angle are not 

shown in this figure. The reference contact angle decreases from 20 ° one second 

after impact of the measuring drop on the sample with increasing time 

figure 15 

Contact angle as a function of time after droplet placement on the 

different wetting structures and on a polished unstructured sample (reference) 

and stagnates at about 11 °. All wetting structures, 

except B2.3, show a significantly lower 

contact angle of θ c = 10 ° ± 1 ° already one 

second after impingement of the measuring 

drop on the structure and decrease to 0 ° after 

t > 8 s. The determined contact angle on the 

wetting structures B2.2 and B1.4 is already 0 ° 

after two and three seconds, respectively. 

For this reason, the wetting structures B2.2 

and B1.4 were selected and structured at the 

2D-cutting tool tip. 

7.3 Fluid transport of the 

biomimetic structures 

To evaluate the structures, the flow velocity v f 

and the cross section of the transport structure 

A ts were used to determine the flow rate 

to = v f · A ts . With regard to the analogy tests, 

the maximum possible flow rate max in this 

process was determined with the volume flow 

and the number of transport structures N ts 

that can be structured on the 2D-cutting tool 

to max = · N ts . The resulting flow rates max 

for the lubricant as a function of the travel distance 

are shown in Figure 16. The biomi metic 

transport structures provide higher flow rates 

than the simple transport structures, in particular 

due to their higher cross-sectional area. 

For all transport structures, an exponential 

decrease of the flow rate can be observed with 

an increase of the travel distance. For the deep - 

est structures with a depth of 200 μm higher 

flow rates could be measured. 

Based on the results of section 00 and section 

00 different variants were selected to be investigated 

in the 2D-machining experiments 

(figure 17). The structures were generated on 

the entire rake face at a distance of 100 μm 

from the cutting edge. The variants V1 and 

V2, a wetting structure and a transport structure 

were combined and structured on the 

rake face. 

figure 16 

Flow rate as a function of distance traveled in simple transport structures (left) 

and biomimetic surface structures (right) with different depths of the grooves 

figure 17 

Overview of the variants selected for the 2D-machining experiments 

The wetting structures were applied near the 

cutting edge and have a height of 200 μm. The 

transport structures fill out the remaining 

rake face. (figure 16/17) 

8. 2D-machining experiments 

The fabricated tools have been investigated in 

accordance with the introduced methodology. 

For reason of comparability, each testing 

series of micro dosage and moisture lubrication 

was accompanied with a non-structured 

tool. The prepared tool variants are given in 

figure 18. Top row shows initial condition, second 

row presents the rake face condition after 

15 runs with micro dosed lubrication. Bottom 



figure 18 

Overview of biomimetic structured tools 

row illustrates the tools after testing with external 

MQL moisture lubrication. 

It can be seen, that tool variant V3 and V5 

failed. Both tools encountered cutting edge 

damage. It can be assumed that the laser struc - 

ture created a notch effect and hence weakened 

the cutting material to its limit. In terms 

of the variants V1, V2 and V4 the rake face 

performed the testing series without damage. 

(figure 18) 

tool variants 

tool variants 

figure 19 

Effect of biomimetic structures on cutting force response 

figure 20 

Effect of biomimetic structures on friction coefficient 

In terms of cutting performance, the evaluation 

of the cutting forces and the calcu lated 

friction coefficients are relevant. Figure 19 

shows the effect of biomimetic structures on 

the cutting force for both lubrication strategies. 

Micro dosage lubrication indicates an 

ad vantage, which is attributable to a higher 

quantity of lubricant and a more direct supply 

then by external misting. 

Regarding the effect of biomimetic structures 

it is evident, that in case of moisture lubrication 

the tool variants V1 and V3 exhibit 

a strong effect in reducing cutting force responses 

by up to 14 %. In terms of micro dosage 

supply the effect is diminished and only 

apparent for variant V1 with a slight reduction 

by 4 % due to an already lowered force 

signal compared to MQL moisture. Analogous 

to the force response figure 20 depicts the effect 

on friction coefficient. Tool variant V1 develops 

the best cutting performance for both 

lubrication strategies, too. Highest reduction 

is achieved by - 9 % in case of moisture supply. 


23


figure 21 

Effect on chip morphology 

Biomimetic structures also influence chip morphology. In a 

qualitative display (figure 21) effects are evident in terms of 

compactness and curling. With respect to chip extraction, 

small chips are regarded as beneficial. Since cutting length 

was identical for all specimen, the apparent deviation in chip 

length can causally be linked to a higher degree in chip compression. 

This observation is supported by the findings from 

Esch (2021) [37] , proving that micro structured rake faces effect 

the deformation degree within the chip. (figure 21) 

9. Conclusion 

In this work was shown, that the application of micro structures 

has the potential to reduce the cutting force in the process 

by 14 %. Most of the structural variants withstand the 

load. Thus, it was shown that the biomimetic structures can 

be generated by means of ultrashort pulse laser ablation and 

work in the 2D process. Under static conditions, the wettability 

of the micro structures with lubricants was higher than 

the wettability of an unstructured surface. In addition, transport 

structures could be identified which, measured by the 

determined flow velocity and volume flow, correspond to the 

conveyances for MQL. Further structure variants will be tested 

as part of the project, such as honeycomb-like and scalelike 

micro structures. 

In addition, new lubricants are being developed as part 

of the project, which will be tested on the structured tools. 

On the basis of the knowledge gained from this, testing will 

finally be carried out in the milling process. 

Authors information 

Doctor engineer, Philipp Esch, scientific employee (exited) 

Master of science, Kathrin Placzek, scientific employee 

Master of science, Daniel Holder, scientific employee 

Professor doctor, Rudolf Weber, 

head of process development department 

Master of science, Manuel Steck, scientific employee 

Professor doctor, Oliver Schwarz, scientific employee 

Bachelor of engineering, Felix Hartmann, 

scientific employee 

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E. Stratakis; J. Bonse (2017) 

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K. Ijiro; K. Tsujii; T. Shimozawa; T. Hariyama; 

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P. Comanns; S. Bauer; W. Baumgartner (2013) 

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bioinspired by the spermathecae of fleas 

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E. Heiss; K. Winands; M. Schwarz; B. Jüttler; J. Heitz; 

W. Baumgartner (2018) 

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true bugs (Heteroptera): a biomimetic inspiration 

for passive, unidirectional fluid transport 

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Imbibition through an array of triangular posts 

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an Institute of Physics journal 21 46, page 464125 

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C. Werner (2014) 

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a chemical analysis 

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C. Neinhuis; C. Werner (2013) 

Wetting resistance at its topographical limit: 

the benefit of mushroom and serif T structures 

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page 1100 - 1112 

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Surface structure and wetting characteristics 

of Collembola cuticles 

PloS one 9 2, e86783 

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L. Saccardi; F. Brümmer; J. Schiebl; O. Schwarz; 

A. Kovalev; S. Gorb (2022) 

Interaction between honeybee mandibles and propolis 

Beilstein journal of nanotechnology 13, page 958 - 974 

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J. Ju; H. Bai; Y. Zheng; T. Zhao; R. Fang; L. Jiang (2012) 

A multi-structural and multi-functional integrated 

fog collection system in cactus 

Nature Communications 3, page 1247 

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H. Chen; L. Zhang; P. Zhang; D. Zhang; Z. Han; 

L. Jiang (2017) 

A Novel Bioinspired Continuous Unidirectional 

Liquid Spreading Surface Structure from the 

Peristome Surface of Nepenthes alata 

Small (Weinheim an der Bergstrasse, Germany) 13 4 


25


[33] 

P. Zhang; L. Zhang; H. Chen; Z. Dong; D. Zhang (2017) 

Surfaces Inspired by the Nepenthes Peristome 

for Unidirectional Liquid Transport 

Advanced materials (Deerfield Beach, Fla.) 29 45 

[34] 

Y. Zhang; Y. Gan; L. Zhang; D. Zhang; H. Chen (2020) 

Surface-Tension-Confined Channel with Biomimetic 

Microstructures for Unidirectional Liquid Spreading 

Micromachines 11 11 

[35] 

H. Chen; T. Ran; Y. Gan; J. Zhou; Y. Zhang; L. Zhang; 

D. Zhang; L. Jiang (2018) 

Ultrafast water harvesting and transport in 

hierarchical microchannels 

Nature materials 17 10, page 935 - 942 

[36] 

W. Zhao; L. Wang; Z. Yu; Chen, Jieshi, Yang, Jinv (2019) 

A processing technology of grooves by 

picosecond ultrashort pulse laser in Ni alloy: 

Enhancing efficiency and quality 

Optics & Laser Technology, page 214 - 221 

[35] 

P. Esch (2021) 

Untersuchung zur Wirkungsweise von lasererzeugten 

Mikrostrukturen auf Funktionsflächen an 

Bohrwerkzeugen für metallische Leichtbauwerkstoffe 

Universität Stuttgart, Dissertation, Stuttgart (Fraunhofer- 

Institut für Produktionstechnik und Automatisierung IPA) 

Image credits 

figure 1 SEM images of LIPSS-structures on 100Cr6 steel: 

a) ripples, b) grooves and c) spikes, 

D. Holder (own representation) 

figure 2 Procedure diagram in the search for 

biomimetic solutions, 

O. Schwarz (own representation) 

figure 3 2D cutting tools with plane rake face, 

P. Esch (own representation) 

figure 4 Specimen with towering bars for 2D cutting, 


figure 5 Experimental setup in machine tool center, 


figure 6 Force translation model according to 

Ernst & Merchant (1941) [13]; 

H. Ernst; m. E. Merchant: 

Chip formation, friction, and high quality 

machined surfaces (1941); 

List of References number 34 

figure 7 Transport structures 

a) Hose plant (Sarracenia spec.), b) spermatheca 

of fleas, in grey box is a «elementary cell», 

c) + d) Toad lizard (Phrynosoma cornutum), 

«elementary cell», 

a)+b) O. Schwarz (own representation), 

c) + d) M. Steck (own representation) 

figure 8 Wetting structures: 

a) prisms b) shell, 

c) truncated cone-shaped pyramids (also used as 

tranport structure!) inspired by Dysodius lunatus), 

d) tilted steps structure, 

a) + b) from Patent WO 2007/035511 A2, 

c) + d) M. Steck (own representation 

figure 9 Experimental setup for laser processing, 

K. Placzek (own representation) 

figure 10 Schematic illustration of 

ultra short pulse laser ablation, 


figure 11 Ideal cross section of the transport structures 

(a) – c)) and schematic representation of cavity 

formation during laser micro machining, 


figure 12 Implementation of complex 2D-structures, 

(own representation) + picture from O. Schwarz 

figure 13 Generated surface structures: 

LIPSS-structures B1.1 - B1.4, 

biomimetic structures B2.1 - B2.3, 

simple transport structures T1.1 - T1.4, 

complex structures T2.1-2.4, and 

bug structures E1 and E2, 


figure 14 Schematic illustration of the setup for 

contact angle measurements and 

flow velocity measurements, 

https://www.dataphysics-instruments.com/de/ 

produkte/oca/#Images-SchemaOCA + 

own representation 

figure 15 Contact angle as a function of time after droplet 

placement on the different wetting structures, 


figure 16 Flow rate as a function of distance traveled in simple 

transport structures (left) and biomimetic surface 

structures (right) with different depths of the grooves, 


figure 17 Overview of the variants selected 

for the 2D-machining experiments, 


figure 18 Overview of biomimetic structured tools, 


figure 19 Effect of biomimetic structures on 

cutting force response, 


figure 20 Effect of biomimetic structures on 

friction coefficient, 


figure 21 Effect on chip morphology, 


further information: www.ipa.fraunhofer.de 



The revolution in tool handling 

No more need to use sledgehammers and tyre irons 

to open massively heavy tools by hand! The RUD Tecdos 

TS makes tool handling safer and much faster. This innovation 

opens injection tools, punching tools and forming 

tools in a matter of seconds, once again revolutionising 

production, service and maintenance processes. 

By optimising these processes, the RUD Tecdos TS can pay for 

itself in less than a year. That’s great news, not only for managers, 

workshop managers and controllers, but also for health 

and safety officers and employees themselves. Being especially 

safe and ergonomic it makes the RUD Tecdos TS the ideal 

com panion to the RUD Tecdos TM, RUD’s tool-handling 

machine. 

“The RUD Tecdos TS is a real milestone in the history of 

safe and efficient tool handling”, stated Anne Kühling, product 

manager in RUD Ketten Rieger & Dietz GmbH u. Co. 

KG’s Conveyor & Drive division. “The initiative for our latest 

development came directly from the market. No wonder: 

companies often have to separate massive heavy tools by 

hand, using cranes, sledgehammers and tyre irons. Depending 

on the tool this can take between 30 min. and 3 hours, 

and take up the time of up to three members of staff. Other 

machines, such as injection moulding machines or diespotting 

machines, might also be put to use to separate the tool. 

This is very inefficient and has a direct impact on operating 

costs. A solution to this problem had to be found urgently”, 

continued Kühling. 

Separating tools in a matter of seconds 

The RUD Tecdos TS does exactly that. Instead of 3 hours and 

three members of staff, RUD’s innovation needs a maximum 

of 5 min. and one person to complete the entire process. 

The RUD Tecdos TS operates with an opening and closing 

force of 50 kN (corresponds to 5 tonnes). A PLC control 

system ensures effective operation. Carefully controlled force 

and speed ensure tool halves to open gently and close accurately: 

operators can set the degree of force from a theoretical 

0 kN – 55 kN, and set speeds from 0 mm – 2,000 mm per min. 

A lower working height means better ergonomics 

Using the RUD Tecdos TS protects expensive tools and safeguards 

the joints and vertebrae of its operators. Only 380 mm 

high, the contact surface ensures work can be performed 

safely and ergonomically. Another benefit: after opening, the 

operator can work directly on both halves of the tool while it 

is held securely in the RUD Tecdos TS, reducing the downtimes 

required for maintenance. Safety is guaranteed because 

it is simply not possible to operate the RUD Tecdos TS, neither 

by pressing buttons on the machine nor by remote control, 

if anyone is standing between the two halves of the tool. 

A revolution in tool handling: the innovative RUD Tecdos TS 

Compact design thanks to an electrical drive 

The RUD Tecdos TS is driven electrically by RUD’s innovative 

Tecdos Pi-Gamma 2-in-1 chain drive system, which 

was specially developed for horizontal and vertical applications. 

This system is based on a high-performance round steel 

chain, also developed by RUD. The drive system is especially 

robust, low-maintenance and with a long service life. 

“The RUD Tecdos TS’s electrical drive is its distinctive feature, 

because it operates entirely without hydraulics. A hydraulic 

drive not only needs more maintenance, but also 

takes up more space because of the additional hydraulic unit. 

In contrast, the RUD Tecdos TS is a compact all-in-one system”, 

explained Walter Lais, designer at RUD Ketten Rieger 

& Dietz GmbH u. Co. KG. “Its compact construction means 

we’ve been able to bring its contact surface down to 380 mm, 

which is very low. That makes it an excellent, ergonomic 

working height for operators.” 

Perfect handling for any tool 

In its standard version the RUD Tecdos TS is sized for tools 

weighing up to 10 tonnes, but it can also handle lighter or 

heavier tools with ease. The Tool Separator has a 1,300 mm 

x 1,300 mm clamping plate and a sliding and contact surface 

at a height of 380 mm. “Theoretically, anything is possible 

here: we can adjust the machine to handle lighter or heavier 

tools, greater or lesser forces and smaller or greater distances 

between the clamping plates. We can also modify the plates 

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RUD Tecdos TS can also be moved by crane, so it can be used 

just where it’s needed. 

To ensure the greatest possible safety in the workplace, optional 

add-on parts, such as a guard bracket, can be installed 

to complement the automatic stop function which triggers 

as soon as anyone is detected on the Tool Separator. A light 

curtain or protective fence can also be supplied to optimise 

safety in the working environment. Thanks to its radio-controlled 

operator devices, the Tool Separator can also be operated 

safely and conveniently outside the danger zone. 

further information: www.moldhandling.rud.com 


27


LACH DIAMANT looks back on 100 years – 15 th part 

Poly – poly – or what? 

Diamond contra diamond? A reflection on the versatility of diamonds 

Horst Lach, managing director and CEO of 

LACH DIAMANT, agreed to write an ongoing series of 

articles about the development of diamond and CBN 

tools and grinding wheels in modern industries. 

Horst Lach is known as a true industry veteran, and 

we are excited to have this pioneer of technology share 

some insights from his over 60 years of professional 

experience in the diamond tool business. This time 

he reflects on the versatile possibilities of diamonds. 

Today, please do not expect a new thesis regarding diamonds 

as the (still) hardest of all things. Named after the Greek word 

Adamantinos, the unconquerable, natural diamonds grow 

deep below the surface of Mother Earth, under pressure and 

in high temperatures, and are then brought from the depth 

to the surface by humans 

In the 1950’s engineering ingenuity made it possible to 

recreate this natural process in synthesis. The manufacturer 

General Electric succeeded in cultivating the so-called 

“Man Made TM ” diamond under almost 6,900 bar atmospheric 

pressure and at 3,500⁰ Celcius; a development which would 

lead to another industrial revolution within the quickly 

growing serial production industry. 

We cannot imagine today’s world without diamonds. Their 

hardness and invincibility make them a crucial cost-reducer 

for many tool applications in the industry – and their brilliance 

and everlasting beauty makes them fitting jewellry for 

our so much appreciated women. 

It starts with gemstones 

When preparing for the article “Diamond contra diamond?”, 

in 2021, I immediately (regrettably) found information on 

diamonds as much sought-after gemstones. For example, no 

buyer of a polished diamond (brilliant) with a weight of half 

a carat (1 ct = 0.2 gram) would expect that he only has to pay 

“double the price” for a whole carat. The value is not only 

determined by size and purity, the buyer must also take the 

extreme rarity of finding large diamonds into consideration. 

For generations this was typical for the gemstone business 

with natural diamonds. 

Of all companies, the “contra” aspect is now offered by a 

company formerly associated with “De Beers”. Produced in 

synthesis, or “in the laboratory”, the diamonds appear to have 

the purity of colour and clarity (factors of classification) of 

polished natural diamonds (brilliants); there is even a choice 

between white, blue or pink. And best of all: anyone, purchasing 

directly from this consortium, can calculate the price 

based on the carat weight from 0.25 to 2.0. 

for example: the price for 

0.25 ct = 200 US $ 

0.5 ct = 400 US $ 

1.0 ct = 800 US $ 

et cetera, so that a 2-carat diamond would cost 1,600 US $. 

The troubled sales people at the diamond exchanges in 

Antwerp and London and jewellers should know that all of 

these “laboratory diamonds” are marked as such with microscopically 

small imprints in order to prohibit “fraudulent” 

mix-ups with natural diamonds. 

Diamond contra diamond – for example, natural diamond 

compared to polycrystalline diamond blades (PCD) 

Diamond contra diamond; for example a single natural 

diamond dresser compared to a diamond dressing roll 



for the first time at the Hanover trade show 

in spring 1973. With them, efficient turning 

machining of copper commutators (and their 

baked-in synthetic mica) was made possible 

for the first time. 

Once again a new technology was born. 

Compact diamond blocks – PCD – were the 

basis for the development of cutting tools, 

superior to carbide tools, for “faster turning, 

drilling and milling with synthetic 

diamonds”. 

As early as 1973 polycrystalline turning tools replaced the overturning 

of copper lamellas of rough and fine polished copper commutators 

Within the industry, the “contra” isn’t playing out as drastically 

In 1957 – after synthetic diamonds became first available – they were initially 

used as diamond grain for the development of new synthetic-resin bond 

diamond grinding wheels, and for the first time also for pre-grinding 

carbides. During the 1960’s, 1970’s and the 1980’s a multitude of innovations 

swept over the market, some of which could only be implemented within 

the industry with certain delays. 

What particularly comes to mind are polycrystalline synthetic diamonds 

(PCD), available since 1973. Simply put, they are synthetic diamond grains 

in a cylindrical shape which – under pressure and heat and combined with 

catalysers tungsten and cobalt – are pressed onto a round carbide plate (as a 

substrate), very similar to diamond synthesis. 

The first PCD plates had a diameter of only 3.2 mm. However, when they 

were mechanically segmented into rectangles, they were the basis for the 

so-called PCD cutting tools, successfully presented by LACH DIAMANT 

Turning of copper commutators is another 

“contra” argument in this reflection. Until the 

use of the first PCD dreborid® turning steel, 

copper commutators were turned exclusively 

with natural diamonds during fine polishing. 

With the result that I had to take my first car 

to the repair shop every 750 km to have the 

wiper motor exchanged; otherwise, the wiper 

could have failed during the next rain. 

And today? Problems with windscreen wiper 

motors? No thank you. PCD turning means 

they should last multiple car-lifetimes. 

A similar “contra” – clearly in favour of PCD – 

can be reported of turning motor pistons. Until 

the 1970’s I could observe high class automobiles 

broken down by the roadside when I 

was driving to the Hanover trade show, apparently 

due to piston seizure. At that time expert 

drivers were convinced they had to “breake 

in” their brand-new cars on this route. If the 

motor could stand it, it was a good car… 

The introduction of polycrystalline cutting 

tools in the aluminum processing automobile 

industry also uncovered this “contra” 

in piston manufacturing as well as the insight, 

that the surface quality achieved during 

turning with polycrystalline cutting materials 

– instead of the thus far used natural diamonds 

– allowed for a perfect lubricating film 

which immediately prevented piston seizure 

to the greatest possible extent. 

Another argument in our reflection on 

“diamond contra diamond” brings composite 

and wooden materials and their respective 

industry into focus. 

Indirectly, carbide is partially involved in 

this example of “contra”, since diamond is 

also present in the grinding wheel for carbide: 

pars pro toto. 

PCD chip milling of glass fiber reinforced plastic (GRP) during an experiment 

in 1974 – compared to diamond-tipped tools, very little dust formation 

Early on, after the successful use of PCD 

turning, drilling and milling tools, other 

non-ferrous materials, such as aluminum and 


29


PCD tool during front facing 

of an aluminum rim 

A diamond cut-off wheel, 

electroplated with diamonds during the 

cutting of a GRP (glass fiber reinforced 

plastic) component 

copper as well as some plastic materials were tried in experiments. 

Examples are soft and hard plastics, glass fiber and 

carbon fiber materials, electrographite carbons and miscellaneous 

wooden materials. 

The photo on the previous page was taken during these 

adventurous times. It shows a PCD end milling cutter during 

the chip machining of a GRP component. 

When the second productronica was held in Munich in 

1977, PCD tools for sawing/scoring/milling/drilling were 

demonstrated to an astonished audience on an Amacher 

electronic circuit board machine, which had been purchased 

especially for this purpose. It was so successful that for the 

time being – until the discovery of spark erosion – expectations 

of the relevant industry had to be disappointed. 

Other industries had now become just as curious and 

further experiments and construction continued diligently. 

For example, machining of carbon fiber components for the 

aircraft industry, which in turn should initiate revolutionary 

successes in the development of spiral drills, especially 

for one manufacturer. And a real “contra” should become 

clear during the machining of composite materials. A pro 

and contra for some imminent problem solutions. While 

using the same diamond material, different production 

and tool technologies created controversies. For the first 

time, PCD tools and the already “tradition-rich” diamondcoated 

electro-plated tools were in competition with one 

another. 

Special advantages of electro-plating 

Almost all profiles projected onto steel bodies can be coated 

with diamond and re-coated after wear in service. The 

diamond grains applied to the surface of the steel body allow 

good removal rates – depending on grain size – which is especially 

advisable for deburring tasks. They are versatile in use, 

like cut-off wheels up to high diameters, or for cutting GRP 

and other hard materials. 

The disadvantage: dust formation which must be extracted. 

LACH DIAMANT provides a special solution for hollow 

drills, featuring extraction directly at the tool. 

Special advantages of PCD 

As far as the geometries of the composite component to be 

machined allow, turning and milling operations can be performed 

efficiently and without any problems, and can therefore 

be recommended accordingly. Profile and drilling tools 

can constructively be equipped with PCD cutting edges, 

which is especially advantageous for larger production numbers. 

Further advantages result in comparison with electroplated 

diamond tools, e.g., grooving tools with exact tolerances 

for corners and radii for serial production. Chips, 

produced during machining, can be extracted very well. 

PCD blades can be reground several times. 

Diamond tools have become an intrinsic and valuable 

part in the world of technology, especially during the last 

50 years. The list of examples above could easily be extended 

– innovative spirit and (positive) thinking outside the box 

will con tinue to enrich “pro and contra” in many industries 

and many applications. For example, let’s think of the natural 

diamond as a single tool for dressing and profiling of grinding 

wheels – it was replaced as a single point dressing tool by 

a chain of innovations in serial production. Roughly in the 

order of the following developments: by the multi-point 

dresser, the Diamant-Fliese or rather dressing plate and – up 

to date – by diamond dressing rolls. 

When we focus at last on the diamond itself, we wonder 

whether it will really stay the hardest of all things? Personally, 

I am not so sure about that. A “contra” could be in the making 

here too. Recently the press featured a “glass” which supposedly 

could score even the surface of a diamond… 

Horst Lach 

further information: www.lach-diamant.de 


news & facts 

Entrepreneurial personality Lothar Horn has died 

Horn Group mourns the death of its longstanding corporate leader 

The entrepreneur Lothar Horn passed away February 

5 th , 2023 at the age of 66 after a long, serious illness. 

Lothar Horn was the managing director of Paul Horn 

GmbH in Tübingen. 

He shaped the Horn Group into an internationally successful 

manufacturer of precision tools with production sites in 

England, Italy, the Czech Republic and the USA. There are 

additional subsidiaries in France, Hungary, China, Mexico, 

Turkey and Thailand. Today the company is the largest industrial 

employer in Tübingen. As chairman of the VDMA 

Precision Tools Association, Lothar Horn was the mouthpiece 

of his industry from 2009 to 2019. Lothar Horn is regarded by 

many in the sector as a pioneer and visionary. His son Markus, 

managing director of Paul Horn GmbH since 2018, will continue 

to run the company, now in its third generation of family 

ownership, together with Matthias Rommel, also managing 

director. 

Lothar Horn, a technology enthusiast and business economist, 

joined his parents’ company 1991. Before that he gained 

experience in the IT industry and management consultancies. 

He became managing director January 1 st , 1995. In 1999 

Lothar Horn created new production and administration facilities 

as well as a demonstration, research and development 

center at the Tübingen headquarters. The new building combined 

all business processes in one location for the first time, 

including a coating center. 

In order to further expand its leading position on the world 

market another factory was constructed next to the Tübingen 

headquarters, doubling the production area. Since its completion 

in 2016 it has been the largest industrial building in 

use in Tübingen. 

Trust in technology and people 

“Technology determines costs.” – This sentence epitomises 

Lothar Horn’s innovative driving force for selling high-precision 

tools on the world markets successfully. The expansion of 

production and administration buildings also involved the reorganisation 

of processes. Additionally to production and administration, 

the qualification and customer training took on 

increasing importance and space at Paul Horn GmbH under 

Lothar Horn’s direction. The Horn Academy is an investment 

in people and employees. In addition to internal and external 

training of people, it also offers apprenticeships, dual study 

programmes, retraining and further education. The facility 

cooperates with the chamber of industry and commerce and 

the Baden-Württemberg Cooperative State University (DHBW). 

It all depends on the right people in the company, was 

Lothar Horn’s conviction. He relied on freedom, trust and a 

culture that allows mistakes as well as the opportunity to learn 

from them. People were just as important to Lothar Horn as 

technology or modern processes. “His appreciation was for 

our customers as well as our employees,” says his successor 

Markus Horn, describing his father. 

Lothar Horn passed away February 5 th , 

2023 at the age of 66 

“No car drives, no plane flies (...) without 

precision tools being used” 

For ten years, in addition to his entrepreneurial activities, 

Lothar Horn was chairman of the Precision Tools Association 

of the German Engineering Federation (VDMA). 2019 his 

role as official representative of the trade organisation came 

to an end. “No car drives, no plane flies and no artificial joint 

can be inserted by doctors without precision tools being used,” 

was one of Lothar Horn’s central statements. Paul Horn GmbH 

is an important and visible player in the industry: hall 10 at 

the Stuttgart trade fair center bears its name. 

A jury of experts awarded Lothar Horn the Tool and Mould 

Making Medal of Honour at the Moulding Expo trade fair in 

Stuttgart, 2021. It honours personalities who, as pioneers and 

visionaries, have set groundbreaking benchmarks and are role 

models. The jury said of Lothar Horn: “Even though he 

directs and manages a really big company in the industry, he 

has remained true to himself over all these years, close and 

approachable for everyone. A human being.” 

Committed to the people of Tübingen 

The internationally active company leader Lothar Horn 

remained loyal to the Tübingen location. The Horn Group offers 

jobs and apprenticeships for 950 employees at the headquarters 

and 1,500 worldwide. This makes Paul Horn GmbH 

the largest industrial employer in Tübingen. Lothar Horn 

was also loyal to the people of the city. Paul Horn GmbH supports 

social institutions as well as the youth and youth development 

work of sports clubs, for example. A visible sign 

of this is the Paul Horn Arena for competitive, amateur and 

school sports in Tübingen. 

The entire Horn Group mourns with the family. 

further information: www.horn-group.com 


31

news & facts 

Rineck shrink fit tooling and machine technology 

now available from Platinum Tooling 

Platinum Tooling, the importer and master distributor of live tools, 

angle heads, Swiss machine products, knurling and marking tools 

manufactured by various international suppliers, is now the importer 

of Rineck shrink fit tooling and shrink fit machine technology in the 

United States and Mexico. 

The announcement was made by Platinum Tooling president Preben Hansen, 

at their headquarters in Prospect Heights, Illinois, near Chicago. 

Established in 1966 Rineck started as a job shop for small parts, then 

became a producer of hydraulic parts for the mining industry and is now 

a globally recognized manufacturer of tool holding technology. Rineck’s investment 

in state-of-the-art manufacturing equipment and commitment to 

innovation, research and development allows them to constantly look for 

ways to achieve the optimal balance of quality, consistency and affordability. 

Rineck offers standard and custom shrink fit tool holders with various 

connections including CAT, HSK, BT, SK, PSC and straight shank 

extensions. In addition, ER shrink fit collets are available. For added rigidity, 

flange or dual contact holders are available for CAT and BT tapers. A clamping 

range from 3 mm to 32 mm is possible for both slim and standard styles. 

All tools are available in inch and metric sizes. 

Rineck produces a wide range of standard shrink fit tool holders as well as 

custom tooling. In addition to standard 4.5 ° taper tools, 3 ° slim and extra 

slim tools are available. Most holders come standard with length adjusting 

screws. Coolant delivery to the cutting tool can be achieved either through 

the center or flange of the tool holder utilizing coolant jets or slots. 

In addition to shrink fit tool holders, Platinum Tooling will offer shrink fit 

machine technology. 

Equipped with an elevation cooling system, heated tools can be moved to 

a cooling tank with a push of a button. The machine’s smart design keeps 

accessories stored but close at hand during operation. 

For this new line of shrink fit tooling and 

machine technology, Platinum Tooling will 

handle application engineering, sales and 

service through a network of distributors 

across the United States and Mexico. 

further information: www.platinumtooling.com 

CNC technology leader opens 

second facility in China 

CNC specialist NUM has opened a second branch in China, further 

consolidating its position within the country. 

As a leader in high-end CNC technology, NUM is represented in virtually 

every industrialised country in the world. In addition to its headquarters in 

Teufen, Switzerland, the company nowadays operates 13 strategically located 

facilities around the globe, together with an extensive network of representatives 

and customer support agencies. 

In China NUM has until now operated a single facility, located in 

Shanghai. The addition of this second facility – based in Guangzhou in the 

south of the country – means that the company is significantly increasing its 

local presence in the area. The facility will provide customer-focused sales 

and application development, as well as enhanced customer support services. 

Guangzhou is the capital and largest city of Guangdong province, situated 

about 120 kilometers (75 miles) from Hong Kong. The region features a 

large number of private companies involved in the construction of special 

NUM office in Guangzhou, southern China 

machines, representing a potentially large 

market for the type of tailor-made technical 

control solutions offered by NUM. 

further information: www.num.com 


news & facts 

VOLLMER’s 15 th subsidiary founded in Thailand 

VOLLMER has opened its 15 th subsidiary under the name 

VOLLMER Asia Pacific in the Thai capital Bangkok. The branch 

will serve the Southeast Asian region – primarily customers from 

Thailand, Vietnam, Malaysia, Taiwan and the Philippines – providing 

them with grinding and eroding machines, services and digital 

solutions locally. 

VOLLMER has been present in the Asian market for many decades. The company 

opened its first Asian branch in Japan 2000, followed by offices in China, 

South Korea and India. With VOLLMER Asia Pacific based in the Thai capital 

Bangkok, VOLLMER is now well placed to further expand its business 

in the ASEAN states (association of Southeast Asian Nations), which include 

Thailand, Vietnam, Malaysia, the Philippines, Indonesia and Singapore. 

Since 2017 VOLLMER has been present in Thailand through a representative 

office, so this dedicated branch constitutes another company milestone 

in Southeast Asia. With a team of seven employees and the support of dealers 

based in the region, VOLLMER Asia Pacific will serve customers locally in 

countries such as Vietnam and Malaysia. The subsidiary will be managed by 

Andreas Weidenauer, who had already run the representative office and has 

more than 30 years of experience in the sector. 

The market for German engineering has continued to grow in the ASEAN 

territories. Both in the metalworking and woodworking industries, demand 

for VOLLMER grinding machines for both carbide-tipped circular saws and 

for grinding and eroding machines for rotary tools is constantly rising. Tool 

manufacturers use VOLLMER machines to produce cutting tools such as 

drills or milling cutters made from carbide or tipped with PCD. 

further information: www.vollmer-group.com 

In the Thai capital Bangkok the Swabian 

sharpening specialists VOLLMER has opened 

its 15 th subsidiary under the name 

VOLLMER Asia Pacific 

SUSTAINABILITY by performance and precision 

The CHIRON Group publishes its first sustainability report 

Grow profitably, acquire market shares, boost global business: the 

CHIRON Group will be pursuing ambitious objectives over the next 

few years. To help achieve this the company is setting itself apart 

from the competition with its product range. The company’s commit - 

ment to sustainability, an important topic for the future, gives 

customers and potential customers even more reasons to choose 

the CHIRON Group. 

The company has already achieved its first major success in this area: from 

the end of the year, production at the German sites will be carbon-neutral. 

The CHIRON Group documents the measures it has taken and the success 

it has enjoyed so far in its first sustainability report “SUSTAINABILITY BY 

PERFORMANCE AND PRECISION”. 

“Our objective is to achieve environmentally conscious and carbon-neutral 

production – the sooner the better,” states CEO Carsten Liske. To this end, in 

recent months, the CHIRON Group has been focusing on developing a global 

sustainability program. And by investing in heat recovery and photovoltaic 

systems, as well as purchasing the required energy from renewable sources, 

the first milestone has already been reached: production operations at the 

CHIRON Group sites in Germany are now carbon-neutral. CHIRON China 

will soon follow suit in 2023 with a photovoltaic system for the Taicang Innovation 

Factory, while plans are already underway 

at CHIRON Croatia. 

Benjamin Kurth, global program manager 

sustainability, explains that, as a machine tool 

manufacturer, the CHIRON Group faces a 

double challenge: “Firstly we are striving for 

carbon-neutral production at our company 

and, secondly, we want to ensure that our customers 

conserve resources and operate machining 

centers and manufacturing solutions 

ever more efficiently.” As a founding member 

of the VDMA Blue Competence Initiative, the 

CHIRON Group actively advocates for sustainability 

concerns and systematically implements 

the defined criteria in its products. 

Alongside successful in the long term.” 

The online version of the Sustainability 

Report 2021 is available on the CHIRON Group 

website under “Environment and Quality”. 

further information: www.chiron-group.com 


33

news & facts 

LACH DIAMANT – 100 Years 

Tradition. Passion. Innovation 

part 4 (from 1957 to 1972): 

How NASA gave wings to a new product 

“When I held my first diamond in my hand in 1908, I would not 

have imagined that one day diamonds would not only be used in the 

automobile industry but also for the machining of wood and plastics”. 

Jakob Lach, the company founder, said this on camera in 1980. 

It would become the preface for the first presentation of a new technique 

for machining wood and plastics – using diamonds as cutting 

material – the Dia Tool. This video, with audio translated into 

multiple languages, has lost none of its relevance for the choice of 

appropriate tools within the furniture, flooring and plastic industries; 

the video can be viewed at: https://bit.ly/LACHDIAMANT 

In 1957 a beeping earth satellite had us look up at the sky, almost in disbelief; 

however, twelve years later, a much broader based media world brought 

it to our attention that a new era had long since begun. This was on July 20 th , 

1969, the first controlled landing of a human on the moon. For the first time 

in the history of mankind, a human set foot on a foreign planet. 

Before both events, we find the development of the first synthetic diamond, 

at that time referred to as “Man-made diamond” by manufacturer 

General Electric. 

The beginning of a “diamond age for technology” was marked like this: 

for ever-advancing development and precision, which would show its first 

universally recognizable proof with the landing of an earth vehicle on the 

lunar satellite. 

Company founder Jakob Lach, 1894-1984 

(photo taken in 1980) 

Accompanying steps and marks 

for the course of LACH DIAMANT 

from now on: 

As of 1969. Space at the original building, 

company headquarters, and at the parental 

home – at Bruchköbeler Landstrasse 39 in 

Hanau – was getting tight, both, in the shop 

and in the office. Not to mention the limited 

use of my parents’ living space. Month after 

month, the sales of resin-bond diamond 

grinding wheels “K-MC” hit new record numbers; 

a result of metal-coated diamond grains, 

processed since 1967, which made grinding 

carbides economically feasible for the very 

first time. 

In 1968, Jakob Lach gave the go-ahead 

for building a factory and multistory office 

building on plot number 41, a hitherto fallow 

property. Turning and grinding machines, 

and modern high-performance heat presses 

for the manufacturing of wheels were ordered, 

and new skilled workers were hired. The move 

to the new building happened in 1969/70. 

Everything seemed to be secured for the 

five-year growth plan for the natural diamond 

cutting shop, and for manufacturing and servicing 

diamond dressing and turning tools 

for the overturning of copper commutators 

(Bosch, Siemens, AEG etc.). 

Original building at Bruchköbeler Landstr. 39, the diamond cutting shop 

and the first addition for manufacturing grinding wheels 

Differently than expected 

And then a development came along which 

the initial provider of “Man-made diamonds” 

(in 1957) had probably expected to happen 


news & facts 

Horst Lach (right) and Kurt Wagner (†) in a section 

of the cutting shop for industrial diamonds 

Metal-coated Borazon® – 

cubic crystalline Boron nitride grains 

quite differently. In the beginning of 1969, quite suddenly and 

unexpectedly, the grinding industry was confronted with an 

abrasive that had not existed (in the Western industry) until 

then: “cubic boron nitride” under the name of “Borazon®”; 

cubic crystalline boron nitride (CBN), with a specific weight 

of 3.48, a thermal resistance of 1,400⁰ C, and an HK of 4,700. 

Though inferior in hardness compared to diamond (diamond 

– HK 7,800), however, significantly superior regarding 

thermal resistance (diamond – approx. 820⁰ C). Borazon®/ 

CBN, processed in resin and metal-bond grinding wheels, 

with a great potential for grinding high-alloy hardened steels. 

Today I could insist on the hypothesis that General Electric 

did not target the “small diamond industry” at the beginning 

of their sales campaign for this new abrasive. This can 

be already concluded from the way GE intended to sell this 

new material: not per carat like diamonds, but per gram; in 

doing so, one gram of Borazon® was offered for the hefty price 

of five US dollars (at that time more expensive than gold). 

At that time, traditional manufacturers of grinding wheels 

for the machining of steel did not have any use for this “superior” 

abrasive for the grinding of hardened steels (much 

to the chagrin of GE): in short, all resources for dealing with 

this pricey new abrasive were lacking, starting with personnel, 

laboratory, forming and pressing capacities. 

Coincidence helps 

Since 1963 the industry had learned to produce resin- and 

metal-bond diamond grinding wheels in good quality. But 

what could be done with this new abrasive “Borazon®”, a cubic 

crystalline Boron nitride (short name CBN)? General Electric 

recommended to produce grinding wheels for steel machining 

with it. They suggested to solely use it during wet grinding 

with a cutting speed of 28 m/sec. However, the problem with 

this approach was that the few grams of the sample material 

we received, for our first tests, were not even enough to produce 

a 200 x 10 mm peripheral wheel for a Jung surface grinding 

machine. But why try surface grinding, let us right away 

try the new CBN grain for tool grinding. No sooner said than 

Successful HSS tool grinding with Borazon® 


35

news & facts 

done – the first CBN grinding wheels for tool 

grinding were made: a 125 x 12.5 cup wheel 

and a 11V9-125 x 3 cone cup grinding wheel. 

The final test was planned to be conducted 

at the Simon company in Neu- Isenburg, a 

manufacturer of steel and tool grinding machines, 

and at that time one of our best diamond 

grinding wheel customers. But at first 

we were greatly disappointed. It was neither 

possible to do the test during wet grinding, 

nor did we reach the necessary cutting speed 

of 28 m/sec – we only had an L15 steel grinding 

machine with only 18 m/sec available for 

the cup grinding wheel. “Well, since you are 

already here”, said the machine operator, and 

the test with a clamped-in HSS turning steel 

began. Excellent grinding sound, no “turning 

blue.” The thing worked with the selected 

machine parameters and a CBN volume of 

V120 (12 % CBN per volume) instead of GErecommended 

V240 (24 % CBN per volume) 

of the grinding wheel. For LACH DIAMANT 

the decision was made. By coincidence we 

had found the worldwide first functioning 

Borazon®/CBN tool grinding wheel, and simultaneously, 

we had discovered the correct 

cutting speed for dry and wet grinding of 

CBN grinding wheels. Despite all subsequent 

experiments with various cooling emulsions, 

still the guiding principle today. 

The complete Borazon®/CBN grinding wheel portfolio, 

already presented at Hanover trade show in 1969/70 

The first Hanover Spring trade show 1969 

was on the horizon. Another historical decision 

was made: the long-stretched large LACH 

DIAMANT stand was immediately divided 

into two halves: on one side diamonds, on the 

other Borazon®. Slogans like “Borazon® easily 

resolves HSS problems” instantly became part 

of the LACH DIAMANT statements. 

The Borazon®/CBN programme soon included 

resin-bond grinding wheels (named 

K-MX7 for dry grinding, and K-MX3 for wet 

grinding), as well as metal-bond CBN grinding 

wheels (Bz-MX) and electroplated abrasive 

wheels (G-MX). 

Showing the claws 

Already a year later, in 1970, LACH DIAMANT 

surprised with “tressex® shows its claws”, 

Borazon®/CBN grinding wheels, for the first 

time produced based on the available polyamide-resin 

bonds. 

Hanover trade show visitors were enthusiastic, 

because it was the first time they witnessed 

the production of HSS chips during dry 

deep grinding with a Borazon®/CBN grinding 

wheel with tressex® on a Saacke UW3 universal 

tool grinding machine, material EW9C04. 

The excitement about the successes of this GE 

Start with Borazon®, the abrasive of a new age 


news & facts 

Made visible for the first time: 

HSS turning chips after grinding with 

Borazon®/CBN 

Borazon®/CBN abrasive wheels with electroplated bond for 

internal cylindrical grinding 

innovation was so great at LACH DIAMANT 

that we decided to approach NASA with a 

request to use their “spider” picture of the 

landing on the moon in our advertising for 

Borazon®; we were given permission! 

A never-before-seen advertising campaign 

with folded post cards (postage seven 

Pfennig at the time) was launched three 

times a week, with various messages on the 

advantages of grinding with “Borazon®/ 

CBN grinding wheels”. It was so successful 

that suddenly “Borazon®” was attributed to 

LACH DIAMANT. Understandably this was 

not to the liking of other subsequent competitors; 

upon GE’s request, we began to “only” 

advertise LACH CBN in the mid-1970’s. 

The unanticipated rapid success of the 

Borazon®/CBN grinding wheel, which gained 

extra momentum by tressex®, made us look for 

additional personnel. 

Customer requests for details on operational 

conditions and application techniques almost 

seemed overwhelming. 

The choice fell upon Dipl. Ing. Günter 

Hobohm, a stroke of luck as it turned out over 

the next decades of our cooperation. From the 

beginning on he was highly motivated and, 

after his hiring in 1970, many written exposés 

show his successful handling of this new 

material “Borazon®”. 

In retrospect, those days were also an exciting 

time in a young, up-and-coming enterprise 

in the diamond tool industry. 

Borazon®/CBN with tressex® for deep grinding 

However, let us not forget that diamond dressing tools, the diamond 

cutting shop for natural turning diamonds, and production remained the 

turnover basis, despite all previously told beginnings of diamond and now 

Borazon®/CBN grinding wheels. 

The following developments of “super abrasives” will give you, my 

cherished readers, further insights into a technical world of upheaval. 

Yours, Horst Lach 

further information: www.lach-diamant.de 


37

processes 

The “smallest” world sensation of 2023: 

The new micro milling cutter 

from Mikron Tool! 

According to the Global Innovation Index 2022, Switzerland is the country with the highest level of 

innovation worldwide. Technology-oriented companies such as the Swiss precision tool manufacturer 

Mikron Tool from Ticino make valuable contributions towards this. This company surprises in fact 

once more with a new development that is well worth seeing. A “small” world sensation. 

The grinding processes for such milling tools 

are extremely demanding; 

the correction range is 0.1 µm (3.94 µin) 

The 250 employee company is presenting its new high-performance 

micro milling cutter designed for roughing and 

finishing the most difficult-to-machine materials. The new 

CrazyMill Cool Micro Z3/Z4 – the smallest with integrated 

cooling and the first with material-specific cutting edge geometries 

– is available in the Ø from 0.2 mm to 1.0 mm 

(.008“ – .039“) with a milling depth of up to 5 x d. 

Designed for high-performance materials such as stainless 

steels, titanium and titanium alloys, heat-resistant alloys (e.g. 

Inconel® and Nilo®) and CoCr alloys, it offers a significant 

increase in performance and maximum process reliability 

compared to conventional standard products. Above all it 

demonstrates its strengths in side and slot milling as well as 

in milling with spiral interpolation. 

The challenge of miniaturisation 

The increasing miniaturisation of workpieces requires tools 

that are both high-performance and reliable, even for the 

smallest applications. They are increasingly sought after in 

medical engineering, in the watch and jewelry industry and 

in the electronic hardware industry. In response to this need, 

Mikron Tool has developed an exceptional new milling cutter 

for micro-machining. For the first time the engineers at 

Mikron Tool have succeeded in transferring complex highperformance 

cutting edge geometries to micro milling cutters. 

This requires a high level of expertise, not just in develop 

ment work. From a production point of view, it is also a 

major challenge to implement such complex geometries in 

milling cutters with Ø smaller than 1.0 mm (.039”). 

The smaller the cross-section of the tool, the more demanding 

is manufacturing them while maintaining quality 

requirements and tolerances. This requires state-of-the-art 

high-precision grinding centers and diamond grinding wheels 

with ultra-fine grit. 

High-precision digital measuring equipment is used 

throughout the production process to ensure the high 


processes 

This allows for the first time, high-performance milling of 

hard and difficult-to-machine materials in micro-production. 

Furthermore the material-specific geometries process the 

material so perfectly that the formation of burrs is practically 

avoided. 

Tool deflection is a thing of the past 

Tool deflection during milling is a considerable problem 

with small tool diameters, which is further exacerbated with 

materials that are difficult to machine due to higher cutting 

forces. 

The grinding specialists of the nanotool department, 

who developed the grinding processes for the new 

CrazyMill Cool Micro Z3/Z4 

picture copyright Thomas Entzeroth 

quality standards, including custom-made digital microscopes 

with up to 2000 x magnification. This is not enough 

on its own. Thanks to the competence of the grinding specialists 

in the nano-tools production department, Mikron 

Tool produces these milling cutters with absolute maximum 

precision in the correction range of 0.1 µm (3.94 µin). This 

demands highly meticulous grinding skills from the grinding 

machine operator. 

The newly developed geometries prevent tool deflection 

by combining high cutting ability with robustness, depending 

on the material which inevitably leads to greater overall 

tool stability. The result: significantly higher removal volumes 

with perfect contour accuracy and significantly longer tool 

life. 

Stay cool! 

High temperatures and temperature changes around the 

cutting edge are extremely critical issues for any high performance 

materials used in milling processes, especially 

when it comes to micro-manufacturing. Mikron Tool benefits 

from its pioneering role in milling cutters with integrated 

cooling. The revolutionary and proven cooling concept (patented) 

of the CrazyMill Cool milling cutter series has been 

transferred to the new micro milling cutter – including the 

smallest diameters! – which leads to excellent results. 

New material-specific cutting edge geometries S 

and SX 

The specific material properties and the very different machining 

behaviour associated were one aspect that played a 

decisive role in the development of this milling cutter. The 

R&D department therefore took a close look at this issue during 

the development of the new milling cutter, and the result 

was remarkable. Two main groups of materials were defined, 

for each of which a specific cutting geometry was developed: 

■ Geometry S was specially developed for stainless steels, 

structural steels, non-ferrous metals and titanium alloys. 

It is characterized by a higher cutting capacity for materials 

with a specific cutting force of less than 2250 N/mm 2 

(326'335 psi). 

■ Geometry SX, featuring a special cutting edge protection, 

is suitable for materials with a specific cutting force greater 

than 2250 N/mm2 (326'335 psi) such as heat-resistant 

alloys and CoCr alloys. 

At the heart of the cooling concept are the cooling channels 

integrated into the tool. Thanks to their special shape 

they deliver significantly more coolant into the milling area, 

resulting in constant and more efficient cooling of the cutting 

edges. 

This enables to achieve the highest cutting values and 

significantly better material removal (compared to commercially 

available micro cutters). 


39

processes 

Up to 2 times longer tool life, up to 3 times shorter milling processes 

with excellent surface quality; the new high-performance geometries 

of the micro cutters are sensational 

Elio Lupica, the new COO at Mikron Tool, 

is convinced: process-reliable milling with 

maximum efficiency is now also possible in 

micro production thanks to the ingenious 

material-specific cutting edge geometries 

In addition the massive cooling jet flushes the chips away from the 

machining area which means that repeated cutting of the chips does not 

take place. The result is excellent tool life and an ultrafine surface finish. 

Edge wear prevention down to the µin range 

To produce precise geometries and ultra-fine cutting edges, the right choice 

is important concerning the carbide the tool is made from. To meet the high 

demands Mikron Tool relies on state-of-the-art ultra-fine grades with high 

wear resilience combined with high fracture resistance. The grain size here 

is less than 0.5 µm (19.69 µin). 

Mikron Tool also uses the most up-to-date coating technology. The new 

revolutionary Exedur SNP coating offers excellent wear resistance even at 

extreme operating temperatures. The high layer smoothness and the precise 

uniform layer thick ness evenly protect all contours without impairing the 

cutting ability. 

Based to this coating tool life is significantly increased, which results in a 

high level of process reliability. As the coating is chrome free, a cross contamination 

on medical parts is avoided. 

First empirical values from the 

field of medical technology 

The first small series of the new CrazyMill Cool Micro has already rolled 

off the production line and is in the test phase at a medium-sized medical 

technology manufacturer. The company manufactures components for 

surgical instruments on six turn-mill centers. The producer was looking for 

a micro-machining solution for martensitic chrome steel. They were unsatisfied 

with the micro-milling cutters they had used and were looking for 

alternatives. Mikron Tool recommended geometry S for milling martensitic 

chrome steel. Milling quality, tool life and burr formation have greatly 

impressed the customer and enables him now to run unmanned shifts. 

This is the first report from the medical manufacturing sector on the latest 

high-performance micro milling cutter series from Mikron Tool. 

A star is born 

“Practical experience shows that Mikron 

Tool has once again hit the jackpot with this 

development. The fact that this tiny tool delivers 

high performance can also be seen from 

a chrome steel roughing application that we 

carried out in our technology center: 

Ø = 0.6 mm (.0236”); n = 30 000 rpm; 

ap = 0.5 mm (.0197”); ae = 0.08 mm (.0031”), 

the feed rate of the milling cutter is 

540 mm/min (21.26 in/min). 

For a 0.6 (.0236”) solid carbide milling 

cutter, these are outstanding values that 

set new benchmarks,” 

says Elio Lupica, COO at Mikron Tool. 

“As an innovative and agile cutting tool 

manufacturer, we are technology-driven and 

continuously invest in research. The best 

thing is that our employees always drive these 

developments actively forward with a high 

level of motivation. The cooperation between 

the grinding department and R&D on this 

project was an extraordinary team effort. 

With this new development, we have ensured 

the reliable and economical production of 

components in the smallest of dimensions, 

now also in high volume production. A star 

is born!” 

further information: www.mikrontool.com 


processes 

Machining graphite: 

Reliably and unmanned 

Test result 

graphite electrode 

TELKOM-OT d.o.o. is a mould and tool manufacturer 

founded in 2006 in Pesnica near Maribor. The 

company, which is located near the Slovenian-Austrian 

border, has currently 22 employees and specialises 

primarily in the development, production, marketing 

and maintenance of die-casting, injection moulding 

and trimming tools. Because EDM plays a central 

role among the production processes a lot depends 

on efficient graphite machining. A real breakthrough 

came with the cooperation with Hufschmied 

Zerspanungssysteme. 

TELKOM-OT has modern technical equipment and qualified 

personnel. The business process is supported by the LARGO 

information system. It ensures communication between 

the individual units of the company. And it is the basis for 

direct cooperation with suppliers of castings for car factories 

and other system suppliers of car parts. Well-organised production, 

the highest quality and a quick response to customer 

requests are the basis of success and the foundation for 

the company’s further development. To improve the utilisation 

of the machines, those responsible at TELKOM-OT 

examined which time-consuming machining operations 

could run unattended overnight. This would have been an 

interesting option for electrode production, but there was a 

problem: “If you want to keep production running overnight 

without workers, the process must be reliable and maintenance-free. 

One aspect worried us: until now, we didn’t 

have a milling tool with a long enough service life to let it 

work all night unattended with a clear conscience,” explains 

Matjaz Krajnc, production manager at TELKOM-OT. 

Background: the difficult material graphite 

Graphite cannot be machined in the true sense of the word, 

as the material is not plastically deformable. Machining does 

not produce chips but breaks grains out of the composite. The 

result is the unloved graphite powder, which not only causes a 

high cleaning effort, but also has a very abrasive effect on the 

cutting edges of the tool – short tool life is the consequence. 

This places high demands on the tool coating. Another challenge: 

since the filigree graphite structures of the electrodes 

break easily, a material-optimised geometry of the milling 

tool must not only ensure optimal removal of the material, 

but also take vibrations out of the machining process and 

reduce forces. 

Specialised tool manufacturer from Swabia 

Matjaz Krajnc and Dušan Žolgar already met before. Dušan 

Žolgar works as a technical advisor in sales at Hufschmied 

Zerspanungssysteme GmbH. The company from Bobingen 

near Augsburg specialises in the development and production 

of process-specific tools that achieve good results, especially 

where materials cause problems: glass and carbon fiber 

composites, plastics, ceramics, hardened steels up to 72 HRC 

– and graphite. “When optimising milling processes, several 

factors have to be coordinated: the toolpaths must exhaust 

the possibilities of the machine and the tool, while being 

matched to the material and the quality requirements of 

the workpiece,” says Dušan Žolgar. This attitude convinced 

Matjaz Krajnc to test the tools. 

“In our milling tests we compared the life of the tool and 

the milling results, and evaluated the cost of the tool, the 

num ber of varieties of the milling tool required and the effort 

involved in programming,” says Krajnc. “Hufschmied’s 

Graftor strategy actually offers us clear advantages on all 

fronts, both in terms of cost efficiency and process reliability. 

We can reliably realise the required manufacturing tolerances 

of ± 0.010 mm.” 

The Graftor ® roughing/finishing tool 

The Graftor® series, available in Ø from 0.5 – 12 mm, allows 

roughing and finishing to be combined in one milling operation. 

“The patented 4-flute geometry results in a significant reduction 

in cutting force due to the two opposing cutting edges, 

one pushing and one pulling,” explains Žolgar. “The main 

advantage is that the quality of the finished surface of a fine 

finish can be achieved with high feed rates and stock allowances. 

Finishing of the residual material is possible over the 

entire cutting length.” Graftor® tolerates depth infeeds (ap) 

up to 2.5 x D with lateral infeeds up to 0.65 x D (ae) and 

can therefore compensate for significantly larger material 

infeeds during finishing. This means that fewer machining 

steps and a smaller number of tool dimensions are required 

to produce the final contour. Due to the low cutting pressure, 

filigree contours can be produced – for example conical 

pins with a Ø of 0.080 mm. The graphite cutters are extremely 

dimensionally accurate to ± 0.005 mm. Each tool is labelled 

with its actual diameter and radius measured on the envelope 

on the shank. The gauge block labelling makes it easy to meet 

the high accuracy requirements of automated production systems 

that operate 24/7. The tool range is characterised by the 

nanocrystalline diamond coating (DIP®) developed and patented 

by Hufschmied for maximum wear resistance. 

Non-productive time is also saved 

“We advised TELKOM-OT and programmed milling strategies 

for existing process parameters so that the company 

could achieve important results from its milling trials,” Dušan 

Žolgar reports. The Graftor tools now process graphite 50 % 

faster. An interesting finding was that the savings are not 

only due to longer tool life, but also because roughing and 

finishing tools are more versatile. Meaning there is no need to 

change between tool types as often. 

further information: www.hufschmied.net 


41

processes 

Measurement solutions from a single source 

in transmission component manufacture 

Haoneng Technology Co., Ltd. 

The Chinese Haoneng Group, a leading manufacturer 

in the field of vehicle transmission synchronization, 

is operating four WGT series inspection machines 

from Liebherr-Verzahntechnik GmbH. These ensure 

the quality of the components providing accurate 

and smooth gear shifting in vehicles. 

Synchronizer rings are key components in manual, auto matic 

and dual clutch transmissions. They help to align the different 

speeds of the gears to enable accurate and smooth gear 

shifting. The synchronization system has a significant effect 

on the efficiency and noise generation of the gearbox. For the 

gearboxes to be efficient, quiet and as smooth as possible, 

accurate and reliable measuring systems must ensure the 

manufacturing quality. 

The Haoneng Group 

One of the world’s leading manufacturers of components 

for the synchronization of vehicle transmissions is the Chinese 

Haoneng Group. The listed parent company Chengdu 

Haoneng Technology Co., Ltd., and its subsidiary companies 

cover together the entire manufacturing process of gearbox 

and synchronization systems. The four companies manufacture 

in the Chengdu, Chongqing and Luzhou sites in the 

Central Chinese province of Sichuan and are suppliers to 

well-known European automobile manufacturers and OEMs. 

Measurement solutions from a single source 

in transmission component manufacture 

Chongqing Haoneng Xingfu Synchronizer Co., Ltd. specializes 

in synchronization systems for vehicles of the midrange 

and luxury classes. The company had ini tially approached 

Liebherr regarding a high-quality inspection machine 

for the quality assurance of its products in 2014. 

Successful test series at the Liebherr site in Shanghai then 

convinced the customer to invest in a WGT 280 from 

Liebherr. 


processes 

Highly accurate inspection machines 

from the WGT series 

Liebherr’s WGT series boasts impressive accuracy, userfriendliness 

and longevity. Lapped granite guides, air bearings, 

precision rotary tables and Renishaw probe systems ensure 

the mechanical precision of the machine. The Liebherr 

WGT measures any type of gear, gear cutting tools and 

other rotation-symmetrical workpieces – individually configured 

by Liebherr according to requirements. Each model 

fulfills the accuracy class of group 1 according to VDI/VDE 

2612/2613 and measures gears from a module of > 0.12 mm. 

The software LHInspect enables automatic correction of setting 

data. It supports the manufacturer neutral GDE interface 

for the exchange of geometric and measurement data between 

gear inspection machine and gear cutting machines 

and opens up the possibility of transferring further production 

and measurement data within the open manufacturing 

landscape LHOpenConnect by Liebherr. 

Impressive in application 

In 2015, the subsidiary Luzhou Changjiang Machinery Co., 

Ltd. also invested in a Liebherr WGT. The company, founded 

in 1964 and the very first manufacturer of synchronizer rings 

in China, required an inspection machine at short notice and 

quickly bought a WGT 280 which had been used as a demonstration 

machine at a trade fair in China. The next order 

came three years later: Luzhou Haoneng Drive Technology Co., 

Ltd., a manufacturer of key components for vehicle trans - 

missions and steering systems, ordered another Liebherr 

WGT 280 

WGT 280. “We were impressed by the performance of the 

WGT in our sister company. This convinced us that this 

was precisely the inspection machine we wanted,” reports 

Jie Zhang, deputy CEO and quality manager at Haoneng in 

Luzhou. Finally, the parent company Chengdu Haoneng 

followed in 2021 with the purchase of a Liebherr WGT 400. 

Production control with the Liebherr WGT 

The Liebherr WGT measures pointing for synchronizer rings 

and involute gear teeth, in some cases with an interrupted 

tooth trace, missing tooth space or missing gear tooth, as well 

as twisting of gears, alignment gearing with involute flanks 

and dedendum fillets. The LHInspect software generates the 

programs for fully automatic inspection on the basis of the 

workpiece data. Parallel, the results and workpiece data can 

be transferred between the production machine and measuring 

instrument via the network and read in. After the first 

part has been manufactured, a control measurement takes 

place on the WGT which plays back the measurement results 

to the production machine, which in turn calculates the correction 

values for manufacture. After the corresponding corrections 

on the machine, series production can begin, which 

then only involves sample measurements. 

Since commissioning in 2015, the system is running without 

disruption or standstills, says Jie Zhang, adding that the 

functionalities of the Liebherr WGT also fulfill the end customer’s 

quality standards. “The Liebherr WGT convinced us 

with its high accuracy and inspection quality, and in Liebherr 

we have found a reliable partner to whom we can turn at any 

time when we need support,” Jie Zhang continues. His company 

can see itself expanding the cooperation with Liebherr 

in the future: “As an efficient and professional provider of 

holistic gearing solutions, Liebherr is a partner we can trust 

for the purchase of further machines, including grinding applications,” 

concludes Jie Zhang. 

Measurement of synchronizer rings for quality assurance 

further information: www.liebherr.com 


43


Appealing state-of-the-art technology 

At the Apex Tool Group GmbH (ATG) in Westhausen 

the S31 cylindrical grinding machine from Studer is 

proving to be truly universal. From individual components 

to medium series, it grinds gear and control 

shafts for electric and pneumatic Cleco assembly tools 

cost-effectively and flexibly. Cleco is one of the six global 

ATG Power & Hand Tools brands. 

The showroom of the Apex Tool Group – formerly Cooper 

Power Tools – in Westhausen boasts an impressive range of 

different assembly tools from the Cleco brand. These include 

pneumatic and electric screwdrivers, either corded or with 

re chargeable batteries, in a straight, angled and pistol design. 

In addition, there are also complete assembly stations with 

an integrated control system that displays screwing assembly 

instructions on a screen, providing the necessary parameters 

for screwing, the monitoring and docu mentation of them. 

The screwdrivers are used, for example, in the assembly of 

com bustion and electric engines, car bodies, transmissions 

and hydraulic units in vehicle manufacturing and in aviation, 

as well as for the automated mounting of wheels on vehicles. 

In order to meet current requirements for high process reliability 

and documented processes, the manufacturer equips 

the assembly tools with sensors for torque measurement as 

well as digital data transmission via cable or wireless (WLAN). 

As Niko Schindelarz, supervisor machining, explains, many 

manufacturers in the global industry consider Cleco assembly 

tools to be very high quality, robust, durable and reliable. 

A major contribution to this, says Niko Schindelarz, is certainly 

the extensive vertical integration at Apex. The company 

produces almost all the essential screwdriver components inhouse 

in Westhausen. This applies in particular to motor and 

gear shafts, levers, valves, cams and housings. 

Flexible for variants and individual features 

“Due to the large number of variants and the increasing demand 

for individual features we need to produce components 

in small series and even as individual pieces at very short 

notice”, explains Johannes Mäule, production engineer in 

Westhausen. As he goes on, this applies to all production 

steps and processes, from turning, drilling and milling 

through to grinding. “We need to grind our motor and gear 

shafts in particular to an accuracy of just a few µm. This is 

essential to ensure the extremely quiet running and long service 

life of our screwdrivers”, adds Niko Schindelarz. But this 

was still very complex until just a few months ago. Only one 

proven grinding machine, purchased back in the early 1980’s, 

was available for cylindrical grinding. In order to grind the 

large number of 30 to 650 mm (1.18” to 25.6”) long shafts with 

diameters between 3 and 65 mm (0.118” and 2.56”), it was 

nec essary to laboriously reset the machine manually, over and 

over again. This was contrary to a needs-based and flexible 

production process. “Most of all, it was increasingly uneconomical. 

Set-up times generally took twice or three times as 

long as the machining times”, explains Johannes Mäule. It 

Electrical and pneumatic screw spindles require grinding of a 

large number of different 30 – 650 mm (1.18” to 25.6”) long 

motor and gear shafts with Ø between 3 and 65 mm 

was also difficult to achieve the required accuracies in diameters 

and cylindricity, especially with long, thin shafts, as Niko 

Schindelarz remarks. As he goes on, this was only possible for 

experienced experts who had been grinding for many years. 

“These experts are currently retiring or will do so in the coming 

years. This means their know-how will no longer be available 

to us. However, the training of young talent is now focused 

on different aspects than it was just a few years ago. 

Manual interventions on machines are more undesirable, and 

the emphasis is on programming and optimal parameterization 

of processes”, explains Niko Schindelarz. 

Generation transition 

In this situation the managers responsible at Apex decided 

to invest in new technology for grinding – as with other machining 

processes, because the changing technical environment 

results in many additional demands on machines and 

production systems. In addition to high flexibility, for example 

options for automated process monitoring and for transferring 

process and production data into a digital network – a 

smart factory. “We need the latest future-oriented technology 

in order to be an attractive employer and inspire much needed 

new talent to come and work in our company”, adds Niko 

Schindelarz. After comprehensive comparisons of different 

machine concepts, he and Johannes Mäule decided to invest 

in a Studer S31 universal cylindrical grinding machine. 

Highly flexible thanks to short set-up times 

As Niko Schindelarz explains, first of all it was necessary to 

carefully prepare the requirement analysis, in order to obtain 

approval for the necessary budget from the commercial manager 

in the US group. “We were able to clearly demonstrate 

on the basis of the operational benefits that the higher initial 

investment – in comparison to competitor products – will 

quickly prove profitable”, agree Johannes Mäule and Niko 

Schindelarz together. The production engineers are now able 

to grind the entire range of shafts on just one machine. The 

S31 cylindrical grinding machine is easily accessible for work- 



piece and grinding wheel set-up, despite the complete enclosure. 

Agreeing with the machine operators, Niko Schindelarz 

praises the excellent working ergonomics in particular. The 

production engineers benefit from much shorter set-up times 

in comparison to previous grinding machines. The special 

Quick-Set function only available on Studer grinding machines 

makes an essential contribution here. Cornelius Wecht, responsible 

for Studer sales in South Germany, reports: “Thanks to 

Quick-Set, the control stores the precise dimensions of all 

grind ing wheels used on the grinding machine. This means 

you can also quickly set up frequently used and repeatedly 

dressed grinding wheels and use them again immediately. 

The control knows the precise dimensions after mounting of 

the grinding wheel and there is no requirement for re-measuring 

or even dressing on the machine.” Another advantage 

for the grinders is the ability to dress profile grinding wheels 

directly on the cylindrical grinding machine. The StuderDress 

software provides the corresponding cycles. With these cycles, 

only the required geometries are rotary dressed on the grinding 

wheel profile. As Niko Schindelarz confirms, this reduces 

set-up and non-productive times, and it also ensures higher 

accuracies and better surfaces on the ground components. 

Ideal for programming in the workshop 

For Niko Schindelarz the control concept of the S31 cylindrical 

grinding machine also offers exceptional advantages. As 

he underlines, the user interface is very easy to understand. 

Graphics and dialogs clearly guide operators and programmers 

through the input fields. The control has also a database 

with all the necessary grinding parameters. “We call this 

StuderTechnology Integrated”, explains Cornelius Wecht. The 

machine operator selects the parameters which the software 

suggests, based on the workpiece geometries as well as the required 

accuracies and surface quality. These ensure that the 

cylindrical grinding machine always reliably achieves a good 

grinding result. The experienced grinder can adapt the suggested 

parameters at any time in order to further optimize 

the grinding process. “The S31 is therefore ideal for use in the 

workshop. Any of our skilled workers trained in machining 

can also work flexibly on the cylindrical grinding machine. 

They do not require any specialized grinding knowledge. This 

gives us maximum flexibility”, says Niko Schindelarz. 

The swiveling wheelhead with two separate grinding spindles 

for straight and angular plunge grinding ensures short 

non-productive times 

Cornelius Wecht, responsible for Studer sales in South 

Germany, Niko Schindelarz, supervisor machining and a 

programmer and machine operator at the Apex Tool Group 

(from left to right) 

Universal thanks to B-axis 

The S31 cylindrical grinding machine at the Apex Tool Group 

in Westhausen has a wheelhead with a B-axis. The wheelhead 

can swivel in steps of 1 °. It comes with two spindle drives, 

one equipped with a grinding wheel for straight plunging and 

the other for angular plunging. This also contributes to short 

set-up times and maximum flexibility. “We can plunge-grind 

a workpiece straight and at an angle in one cycle without 

any set-up work. This means we can completely machine almost 

all components in a single clamping”, Niko Schindelarz 

explains the advantages of the B-axis and stresses: “With 

the equipment we have chosen, the S31 cylindrical grinding 

machine fully deserves the attribute ‘universal’. If there is one 

cylindrical grinding machine that deserves the name, then 

it’s the Studer S31.” After nearly five months, the S31 cylindrical 

grinding machine has proven that it completely fulfills the 

tool manufacturers’ extensive requirements. 

Exemplary consultation and service 

Johannes Mäule cites another important aspect when making 

investments in production systems: “For a special technology 

like grinding, production engineers usually only have general 

expertise. This applies particularly to innovative equipment 

features on machines and their specific advantages in relation 

to individual requirements.” As Niko Schindelarz adds, research 

ing current grinding technology was initially not so 

easy. “But the Studer specialists advised us in great depth and, 

above all, openly and honestly. We were able to develop our 

optimal cylindrical grinding machine configuration together 

in just a few steps”, he continues. This built the necessary trust 

to confidently invest in the expensive S31 cylindrical grinding 

machine. “It was also important for us that service and technical 

advisers are regionally present and can advise and support 

us directly in production within a short period of time. 

This is essential to guarantee that our current and forwardlooking 

investment in the S31 will prove profitable in the long 

run”, emphasizes Niko Schindelarz. He concludes, Studer has 

completely fulfilled all relevant criteria with its specialists 

and the S31 universal cylindrical grinding machine. 

further information: www.studer.com 


45


Laser processing improves quality and tool life and 

secures competitive advantage 

The machining of tools for the wood industry, such 

as saw blades, milling tools, hoggers, jointing cutters 

or form cutters, and of tools used in e-mobility, e.g. for 

stator production, reaches a new level when using the 

LASERTEC 50 PrecisionTool. For the first time tools 

with 0 of 355 mm can now also be machined. 

DMG MORI thus also enables all those tool manufacturers, 

who have larger tools in their portfolio, to switch from conventional 

to laser machining. The plus: laser production is 

many times more efficient than classic EDM and can be easily 

automated by means of automated pallet handling. 

The basis for the new development was above all the increasing 

customer requirements of the tool manufacturers. 

To this day, many toolmakers use the process of wire or disk 

erosion, for example, to realize the finest, filigree contours on 

complex tools. The problem: diamond cannot be eroded, only 

the bonding material is removed. This is where DMG MORI 

sets the tone with the LASERTEC 50 PrecisionTool, simultaneously 

solving the dilemma of difficult-to-erode polycrystalline 

diamond (PCD) types and limited corner radii. Also relevant 

for many tool manufacturers: tool design is now much 

more flexible, as laser machining allows more cutting edges on 

the same diameter without creating a collision. Additionally 

worth mentioning: diamond and binder can now be lasered 

equally well and even coarse-grained PCD is no longer a hurdle. 

In addition, users of the LASERTEC 50 PrecisionTool can 

look forward to a freely selectable cutting edge radius and the 

easy mastering of even highly complex geometries. 

Varied and diverse: tool pallets for the Lasertec 

LASERTEC 50 

PrecisionTool & PH 50: powerful couple for low space 

In the future tool manufacturers who laser instead of erode 

can also expect better performance: until now the best results 

on complex tools could be achieved almost exclusively by two 

to three EDM cycles. The High Speed Mode 3.0 technology 

integrated in the LASERTEC 50 PrecisionTool achieves – com - 

pared to classical machining processes – a reduction of the 

cutting edge chipping by a factor of two. In addition the machining 

time is also reduced and, for example, instead of 

90 min for wire EDM, is now only approx. 35 min for laser 

machining. Thanks to defined cutting edge radii and minimal 

chipping, tool manufacturers will be able to guarantee 

their customers up to 40 % longer tool life and thus greater 

efficiency in the future. And that with up to 56 % lower unit 

costs compared to EDM. 

Keyword efficiency: with the PH 50 – the most compact and 

cost-efficient pallet handling from DMG MORI – tool manufacturers, 

as other users of the LASERTEC 50 PrecisionTool, 

automate their machining processes and stand out from the 

competition due to more performance. Compared to other 

automation solutions, the combination of LASERTEC 50 PrecisionTool 

and PH 50 requires little space (2.7 m 2 ); optimal 

for all companies that want to increase their degree of automation 

in a small space. The basis of the PH 50 is a design 

with three NC-controlled axes. In addition to its precision, 

the compact pallet handling system offers enormous flexibility 

and can be connected to other machining centers in addition 

to the LASERTEC 50 PrecisionTool. The PH 50 can supply 

the LASERTEC 50 PrecisionTool with up to 30 pallets. The 

maximum workpiece weight including pallet – taking into 

account the pallet’s own weight – for the PH 50 is 70 kg; the 

LASERTEC 50 PrecisionTool alone allows 30 kg. The pallet 

handling is controlled directly via the machine control with 

the aid of the PALLET MASTER. The combination of PH 50 

and LASERTEC 50 PrecisionTool allows a cost-efficient entry 

into automated machining of a wide range of tools. 

In addition to the aforementioned tooling for wood processing 

and electromobility, lasers are also the technology of 

the future where super-sharp cutting edges (optical industry) 

or industry-specific cutting edge rounding (composite or 

wood processing) are required. 

further information: www.dmgmori.com 



Machining centers as “green” welding cells 

HELLER enables friction stir welding on all machine series 

Known as a green joining technology for nonferrous 

metals such as aluminum, friction stir welding 

(FSW) has established itself in a number of indus tries. 

In future manufacturing companies using HELLER 

machines will no longer need any additional hardware 

for this technology. Instead they will be able to perform 

this process in a single setup on all their innovative 

4-axis or 5-axis machining centers. 

Friction stir welding is a good choice when it comes to producing 

high quality cavity-free and tight welded joints with 

excellent fatigue properties. Accordingly this process is often 

applied in the manufacture of reservoirs, tanks and containers 

as well as in shipbuilding and aerospace engineering. In 

addition, this joining technology is increasingly establishing 

itself in the electrical industry and in automotive engineering 

with the growth market of e-mobility – for example for the 

welding of battery housings. According to HELLER managing 

director Dieter Drechsler, it provides a number of advantages 

for all areas of application. 

Firstly, the quality produced is very high. Due to the 

comparatively low heat input, a very fine-grained structure 

without cracks or pores is created in the material. Distortion 

in the component is minimal. As a result the welded seam 

meets the highest standards in terms of tightness and crash 

behaviour. 

Secondly, it offers a number of key advantages with regard 

to environmental and health aspects, which is why friction 

stir welding is also referred to as a green technology. The reasons 

for this are: compared to conventional welding methods, 

no dangerous light flashes or hazardous fumes that would 

have to be extracted are produced during the joining process. 

Moreover the environmental balance of the process is very 

favourable because of the low energy consumption. 

Integration into the machining center 

provides high economic efficiency 

Thirdly, the high cost-effectiveness is a real profit driver. 

As no consumables such as cored wire or shielding gas are 

required, consumption costs are minimal. 

The welding process becomes a particularly interesting 

technology with the successful integration into modern 

HELLER machine tools. It allows users to eliminate an additional 

work step and only requires the inexpensive tools, 

activation of the HELLER technology cycle and the ‘adaptive 

control function’ in the Sinumerik 840D sl control. 

The machine operator can easily program the welding path 

at the CNC control panel using G-code. The transfer of CAD/ 

CAM data is also possible without any problems. In order to 

start the welding process, it is also necessary to determine the 

key parameters of pressure and speed. These depend, among 

other things, on factors such as the material composition and 

the required type and depth of the weld seam. According to 

Dieter Drechsler, this task poses a certain challenge. However, 

“our experienced experts are of course there to support 

you if you wish. And initial pilot projects have shown that 

our customers’ machine operators are able to very quickly 

manage this task on their own.” 

Once determined, pressure and speed can be called up via 

a cycle. After the welding process has started, the Siemens 

CNC logs the entire workflow and reliably controls compliance 

with all parameters. Previously required ‘load cells’ are 

obsolete. 

At the same time, the variety of joint types that can be 

produced is quite large. In addition to classic butt joints, 

corner and T-joints are also possible. Even lap joints – single, 

multiple and as a T-variant – can be realised without any 

problems. 

How does friction stir welding work? 

During friction stir welding the pin-shaped rotating tool is 

plunged into the gap between the components to be joined 

with high axial force until the so-called tool shoulder rests 

against the surface of the component. The friction created 

during this process heats up and eventually plasticises the 

component material. As a result the materials of the components 

mix and form a bond in the joint gap. Now the tool, 

which continues to rotate, is moved along the joint gap with 

constant contact pressure, while the material is steadily plasticised 

and mixes around the tool pin. As a result a highquality 

weld seam is created. At the end of the weld seam 

produced, the feed motion is stopped and the tool is lifted 

out of the joining zone. 

Functionality of friction stir welding 

further information: www.heller.biz 


47

components 

Cutting tool measurement and compensation 

Interface is expanded to meet customers’ tooling needs 

As a cutting tool manufacturer, it is imperative to ensure your geometry 

is exact to maintain superior cutting performance. Getting this 

right gives an edge over competitors and is what ultimately builds a successful 

tool maker’s reputation. ZOLLER’s mea sure ment machines and 

ANCA software easily communicate to simplify and improve tool measure 

ment, wheel measurement, form measurement and compensation 

processes. 

This partnership provides key benefits to their customers by automating and 

refining the tool measurement process. 

Background 

ZOLLER measurement machines are widely adopted in the market as an effective 

tool for measuring complex geometry of cutting tools. While LaserPlus and 

iView are very popular and effective tools for in-process measurement of tool OD 

and profiles, the ZOLLER system can automatically measure a diverse range of 

tool features. ZOLLER is typically used for more detailed tool measurement during 

tool setup or intermittently during batch runs to ensure features remain in 

tolerance. 

The old interface including ToolRoom RN33.1 only supported XML format 

but the latest RN34.1 release supports both XML and GDX® (GDX® is a registered 

trademark of ISBE GmbH) interfaces. Release details for both ZOLLER and 

ANCA are as follows. 

Parameter adjustment 

The ToolRoom Measurement Wizard 

remains the easiest way to set up ANCA- 

ZOLLER measurement feedback. This 

guides the user through the available list 

of features for a given tool. The user can 

easily select which features can be measured 

and have compensation applied. 

ZOLLER Pilot 3.0 with program version 1.18.7.20043 

Toolroom RN34.1 

update 52.03 

ToolRoom Measurement Wizard 

Note: the new interface is based on the GDX® platform. It sup ports the GDX® 

format and is compatible with other measurement machines that also support 

the GDX® import/ export. 

Communication method 

Data can be transferred using a USB stick or direct network communication if 

both ZOLLER and ANCA machines are on the same network. 

ANCA-ZOLLER measurement feedback 

In developing a measurement and feedback process, for each parameter/feature 

listed (at the end of this article), ANCA and ZOLLER have worked together to 

agree upon a fixed ZOLLER measurement process and a fixed ANCA grinding 

parameter adjustment to which it is directly linked. Wheel adjustments are not 

supported as an option for this method of compensation. Adjustments are applied 

to parameters for compensation without changing the design parameters. 


components 

The user can also specify the required 

length/angle tolerance for each parameter so 

that values within tolerance will not be compensated 

when returned from ZOLLER. 

When measurement data 

(GDX® file) is imported to the 

ANCA grinder, the measured 

parameters are brought as nominal 

value but compared against 

design value and adjustments 

made accordingly. Values within 

tolerance will not be compensated 

but users have an option to 

override this function. 

Each feature is initially set with a default 

(recommended) location for measurement 

(red line), although this can be manually 

adjusted before sending the data to ZOLLER 

for measurements and tolerance settings can 

be imported from another Tom file to avoid 

resetting again all parameters and tolerances 

individually. 

Note: although the file can be transferred through a network connection, an 

operator is still required to select the correct file, carry tools to the ZOLLER 

machine and apply the compensation on the correct machines. As the AIMS 

(ANCA Integrated Management System) product develops, we intend to offer 

a system that can automatically transfer, measure, compensate tools during 

batch grinding. 

Setting axial position of measurement 

Import from another Tom file 

further information: www.anca.com // zoller.info 


49

fairs in alphabetical order 

AMB Stuttgart, Germany 

(September 10-14, 2024) 

bauma Shanghai, China 

(November 26-29, 2024) 

CIMT Beijing, China 

(April 10-15, 2023) 

DEBURRING Karlsruhe, Germany 

EXPO (October 10-12, 2023) 

EMO Hanover, Germany 

(September 18-23, 2023) 

EPHJ Geneva, Switzerland 

(June 6-9, 2023) 

FABTECH Toronto, Canada 

(June 11-13, 2024) 

FEIMEC São Paulo, Brazil 

(May 9-13, 2023) 

GrindingHub Stuttgart, Germany 

(May 14-17, 2024) 

GrindTec Leipzig, Germany 

(March 7-10, 2023) 

Hannover fair Hanover, Germany 


IMTS Chicago, USA 

(September 9-14, 2024) 

JIMTOF Tokyo, Japan 

(November 5-10, 2024) 

LIGNA Hanover, Germany 

(May 15-19, 2023) 

MACH-TECH and Budapest, Hungary 

INDUSTRY DAYS (May 16-19, 2023) 

METALEX Bangkok, Thailand 

(November 22-25, 2023) 

MOULDING Stuttgart, Germany 

EXPO (June 13-16, 2023) 

Wood TaiWan Taipei, Taiwan 


SIAMS Moutier, Switzerland 

(April 16-19, 2024) 

sps Nuremberg, Germany 

(November 14-16, 2023) 

TIMTOS Taipei, Taiwan 

(March 6-11, 2023) 

current status 

2024 

2024 

2023 




2024 


2024 



2024 

2024 






2024 



trade fair dates as by beginning of Februar 2023; we are not responsible for reliability of these dates 


impressum 

ISSN 2628-5444 

publisher 

Benno Keller 

phone + 49 (0)911 - 2018 200 

fax + 49 (0)911 - 2018 100 

keller@harnisch.com 


Eric Schäfer 

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eric.schaefer@harnisch.com 

managing editor 

Christiane Ebner 

phone +49 (0)911 - 2018 260 

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ebner@harnisch.com 

publishing company 

Dr. Harnisch Publications 

management board 

Dr. Claus-Jörg Harnisch 

Benno Keller 

Eschenstrasse 25 

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fax +49 (0)911 - 2018 100 

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advertising Germany, Austria, Switzerland 

Thomas Mlynarik 

phone +49 (0)911 - 2018 165 

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mlynarik@harnisch.com 

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steinberg@harnisch.com 

advertising USA, Canada 

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advertising China, Hong Kong, Taiwan 

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advertising Taiwan 

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sydneylai@ringier.com.hk 

Four issues per year 

printed by 

Schleunungdruck GmbH 

Eltertstrasse 27 

97828 Marktheidenfeld, Germany 

editorial 

Adelbert Haas GmbH .................6 

ANCA Pty Ltd. ..................... 48 

CERATIZIT 

Deutschland GmbH ................12 

CHIRON Group SE ..................33 

DMG MORI GmbH ................. 46 

Fraunhofer Institute for Manufacturing 

Engineerig and Automation IPA/ 

University of Stuttgart ..............14 

Fritz Studer AG .................... 44 

Gebr. Heller Maschinenfabrik GmbH ..47 

Hartmetall-Werkzeugfabrik 

Paul Horn GmbH ..................31 

HUFSCHMIED Zerspanungssysteme 

GmbH ............................41 

company finder 

Kennametal Inc. ......................9 

Lach Diamant Jakob Lach 

GmbH & Co. KG ............... 28, 34 

Liebherr-Verzahntechnik GmbH ..... 42 

Mikron AG, Division Tool ............38 

NUM AG ...........................32 

Platinum Tooling Technologies, Inc.. ...32 

RUD Ketten Rieger & Dietz GmbH 

& Co. KG ..........................27 

VOLLMER WERKE 

Maschinenfabrik GmbH ............33 

ZECHA Hartmetall- 

Werkzeugfabrikation GmbH ........10 

VAT DE 133 510 873 

The articles contained in this magazine, 

including the illustrations, are subject 

to copyright law. Any use without the 

consent of the publisher is not permitted 

and will be prosecuted. This applies to 

every conceivable form of reproduction. 

Copies and reprints can be ordered on 

request. Articles which are identified by 

name or which are to be assigned to an 

author by an abbreviation do not necessarily 

reflect the opinion of the editorial staff. 

Unsolicited manuscripts cannot be returned. 

If a manuscript is accepted by the editorial 

staff, publishing and copyright law as well 

as all rights for publication and distribution 

are transferred to the publisher. The 

publisher accepts no liability with regard 

to the facts set out in these articles. 

copyright © 2023 Dr. Harnisch Publications 

advertising index 

Adelbert Haas GmbH ................................................front cover 

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

Boehlerit GmbH & Co. KG ...............................................page 9 

CERATIZIT Deutschland GmbH ...................................... back cover 

Kapp GmbH & Co. KG ..................................................page 13 

Lach Diamant Jakob Lach GmbH & Co. KG ....................... inside front cover 

Mikron AG, Division Tool ...............................................page 5 


51

Up2Date February 2023 

Stay tuned and check out the latest product 

developments from CERATIZIT! 

Find out more at: 

cutting.tools/gb/en/uptodate 

CERATIZIT is a high-technology engineering 

group specialised in cutting tools and hard 

material solutions. 

Tooling a Sustainable Future 

www.ceratizit.com

hpt 2023 #1

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