hpt 2023 #2
■ Diamond coatings on cutting inserts ■ Grinding requires smart automation ■ News from LIGNA ■ ■ New tool concept based on the Fibonacci principle ■ Filtration solutions for coatings and finish applications ■
■ Diamond coatings on cutting inserts ■ Grinding requires smart automation ■ News from LIGNA ■
■ New tool concept based on the Fibonacci principle ■ Filtration solutions for coatings and finish applications ■
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ISSN 2628-5444<br />
high precision tooling<br />
Machine Tools, PCD, PVD, CVD, CBN, Hard Metal <strong>2023</strong> – 2<br />
■ Diamond coatings on cutting inserts ■ Grinding requires smart automation ■ News from LIGNA ■<br />
■ New tool concept based on the Fibonacci principle ■ Filtration solutions for coatings and finish applications ■
editorial<br />
It doesn’t have to be Hollywood...<br />
Eric Schäfer<br />
editor-in-chief<br />
...when you talk about a world<br />
premiere. Even if everyone<br />
immediately thinks of the<br />
famous red carpet, moviestars<br />
from the film industry or<br />
the presentation of the latest<br />
model of an international car<br />
manufacturer.<br />
The machine and tool making<br />
industry, on the other hand, is a<br />
little more discreet when it comes to premieres, even though<br />
some trade fairs are a veritable fireworks display of products.<br />
But in the meantime, new and innovative machines are also<br />
unveiled as part of an event.<br />
In this issue of hp tooling a tool manufacturer’s trade fair<br />
novelty bearing the label “world premiere” can be admired<br />
in advance for the first time.<br />
And that brings us to LIGNA, the international trade show<br />
for woodworking and wood processing, which will finally<br />
be held again in Hanover in mid-May after a four-year<br />
break. There the tool manufacturer LEUCO will show a<br />
world premiere: its new tool concept based on the “Fibonacci<br />
principle”. The patent-pending concept for the arrangement<br />
of cutting edges on basic tool bodies has taken nature as its<br />
model when it comes to making optimum use of the limited<br />
space on the basic tool body.<br />
When it comes to producing resistant and intelligent hightech<br />
tools, optimized tool design plays a decisive role and<br />
also the appropriate choice of materials and perfect geometry.<br />
At the Hannover Messe the Fraunhofer IST presented a<br />
sustainable process chain for such tool manufacturing which<br />
we do not want to withhold from our readers. The subject of<br />
tools occupies an extensive space in this issue. So if you are<br />
looking not only for world premieres but also for “normal”<br />
innovations in the tool sector to optimize your production,<br />
you will here find what you are looking for.<br />
Eric Schäfer<br />
editor-in-chief<br />
Come and see for yourself:<br />
www.harnisch.com<br />
Perfectly positioned.<br />
The international specialist magazines from Dr. Harnisch Publications<br />
You can now explore our newly designed website, with a<br />
clear focus on responsive design and easily usable applications.<br />
Alongside the free-to-use digital magazine editions, you will<br />
find bonus news coverage, events, subscription and<br />
general information on all our magazines. Take a look at<br />
www.harnisch.com for all relevant content.<br />
Our publications include:<br />
- Technology & Marketing -
table of contents<br />
cover story<br />
Optimal framework conditions for CFRP machining<br />
Piekenbrink Composite and CERATIZIT are making clean cuts 6<br />
materials & tools<br />
One milling cutter, full flexibility for all milling operations 9<br />
New tool concept based on the Fibonacci principle<br />
Innovations at LIGNA <strong>2023</strong> 10<br />
Configurations extend tool life 13<br />
Modular tooling system for high efficiency 15<br />
Diamond coatings on cutting inserts 16<br />
Development partner for toolmakery 18<br />
A premium solution for hot mill roll grinding 20<br />
Four inserts for stator bores 21<br />
processes<br />
Sustainable process chains for the manufacture of resilient and smart tools<br />
Fraunhofer Institute for Surface Engineering and Thin Films IST 33<br />
Additive-subtractive manufacturing of clamping systems for the<br />
machining of CFRP components<br />
Fraunhofer Institute for Manufacturing Engineering and Automation IPA 34<br />
Design, manufacture and inspection in a smart loop 38<br />
Greater efficiency thanks to digital assistance systems in machine tools 39<br />
machining center<br />
Grinding requires smart automation 40<br />
New femtosecond laser solutions 43<br />
The European debut of the Supfina Fact 44<br />
Precise sharpening for wood and co. 45<br />
components<br />
Filtration solutions for coatings and finish applications 46<br />
The world’s first e-chain made entirely of recycled material 47<br />
The ES951 spindle and MyHSD, a high performance combination 48<br />
Coolant filtration as a value-adding factor 50<br />
news & facts 22<br />
fairs 5, 25<br />
impressum & company finder 51<br />
4 no. 2, May <strong>2023</strong>
fairs in alphabetical order<br />
AMB Stuttgart, Germany<br />
(September 10-14, 2024)<br />
bauma Shanghai, China<br />
(November 26-29, 2024)<br />
DEBURRING Karlsruhe, Germany<br />
EXPO (October 10-12, <strong>2023</strong>)<br />
EMO Hanover, Germany<br />
(September 18-23, <strong>2023</strong>)<br />
EPHJ Geneva, Switzerland<br />
(June 6-9, <strong>2023</strong>)<br />
FABTECH Toronto, Canada<br />
(June 11-13, 2024)<br />
FEIMEC São Paulo, Brazil<br />
(May 7-11, 2024)<br />
GrindingHub Stuttgart, Germany<br />
(May 14-17, 2024)<br />
GrindTec Leipzig, Germany<br />
(March 11-14, 2025)<br />
Hannover fair Hanover, Germany<br />
(April 22-26, 2024)<br />
IMTS Chicago, USA<br />
(September 9-14, 2024)<br />
JIMTOF Tokyo, Japan<br />
(November 5-10, 2024)<br />
LIGNA Hanover, Germany<br />
(May 15-19, <strong>2023</strong>)<br />
MACH-TECH and Budapest, Hungary<br />
INDUSTRY DAYS (May 16-19, <strong>2023</strong>)<br />
METALEX Bangkok, Thailand<br />
(November 22-25, <strong>2023</strong>)<br />
METAV Düsseldorf, Germany<br />
(February 20-23, 2024)<br />
MOULDING Stuttgart, Germany<br />
EXPO (June 13-16, <strong>2023</strong>)<br />
SIAMS Moutier, Switzerland<br />
(April 16-19, 2024)<br />
SIMTOS Seoul, South Korea<br />
(April 1-5, 2024)<br />
sps Nuremberg, Germany<br />
(November 14-16, <strong>2023</strong>)<br />
Surface Stuttgart, Germany<br />
Technology (June 4-6, 2024)<br />
current status<br />
2024<br />
2024<br />
<strong>2023</strong><br />
<strong>2023</strong><br />
<strong>2023</strong><br />
2024<br />
2024<br />
2024<br />
2025<br />
2024<br />
2024<br />
2024<br />
<strong>2023</strong><br />
<strong>2023</strong><br />
<strong>2023</strong><br />
2024<br />
<strong>2023</strong><br />
2024<br />
2024<br />
<strong>2023</strong><br />
2024<br />
trade fair dates as by middle of April <strong>2023</strong>; we are not responsible for reliability of these dates<br />
no. 2, May <strong>2023</strong><br />
5
cover story<br />
Optimal framework conditions for CFRP machining<br />
Piekenbrink Composite and CERATIZIT are making clean cuts<br />
The manufacture of premium carbon eyeglass frames has opened up a whole new segment<br />
for Piekenbrink Composite GmbH<br />
Everything seemed on the up and up for<br />
Piekenbrink Composite GmbH in Laupheim, Germany.<br />
Experts in fiber reinforced plastics, they had established<br />
themselves as the go-to partner for the aviation,<br />
automotive and mechanical engineering industries.<br />
However Piekenbrink CEO and, prescription eyeglass<br />
wearer, Björn Piekenbrink knew CFRP could do more.<br />
So he turned his vision into reality by partnering with<br />
the tool specialists at CERATIZIT and their Monster-<br />
Mill FRP milling cutters.<br />
While fiber reinforced materials are indispensable in the fields<br />
of aerospace, automotive and mechanical engineering, they<br />
also have a reputation for being difficult to work with –despite<br />
boasting excellent properties. The experts at Piekenbrink<br />
Composite GmbH in Laupheim, Germany, however, gladly<br />
accepted the challenge. Founded in 1979 by their father, Olaf<br />
and Björn Piekenbrink have transformed the company into the<br />
go-to partner for established aircraft and automotive manufacturers<br />
and mechanical engineering companies. Where<br />
other composite companies can go no further, Piekenbrink<br />
Composite only just begins. “Companies tend to either form<br />
fiber reinforced materials into the required shape for further<br />
processing or focus on subsequent drilling and milling.<br />
We handle everything – from tool making and model construction<br />
right down to the finished component, in small and<br />
large-scale production. We also manufacture products aimed<br />
at speeding customers’ manufacturing processes and ensuring<br />
an increased reproducibility of their carbon parts,” say<br />
CEOs Olaf and Björn Piekenbrink.<br />
Framing things differently<br />
So, what happens when you work day in, day out with carbon?<br />
“You start coming up with new ways of using the material.<br />
When I started wearing glasses a few years ago I had the<br />
immediate thought to make my frames out of CFRP,” recalls<br />
Björn Piekenbrink. However his optician advised against the<br />
idea, saying it was no easy task. “I put the idea on the back<br />
burner, as I didn’t really feel like putting all that effort into a<br />
single pair of glasses. My wife, however, was much more persistent<br />
and came across Friedrichs’ Spectacles, a manufacturer<br />
that offered carbon eyeglass frames.” That’s how Björn<br />
Piekenbrink finally got his carbon frames.<br />
The story, however, does not end there. David Friedrichs,<br />
the founder of Friedrichs’ Spectacles, reached out to<br />
Piekenbrink Composite to ask whether the company would<br />
be interested in manufacturing the frames for him. “He said<br />
he’d take care of the design and sales, while we’d take care<br />
of manufacturing the different models. I was on board with<br />
the idea as soon as he proposed it. I don’t know a thing about<br />
designing glasses and it didn’t feel like taking care of sales<br />
and marketing, but making the frames that’s right in my element,”<br />
says Björn Piekenbrink. And that’s how the com pany’s<br />
6 no. 2, May <strong>2023</strong>
cover story<br />
journey into a brand-new product field began<br />
– one that was not without its challenges.<br />
CFRP/GFRP: a fine challenge<br />
As it turned out one of the biggest challenges<br />
dealt with was one of the smallest parts: the<br />
narrow slots in the temples, into which titanium<br />
hinge had to be inserted. So Piekenbrink<br />
reached out to CERATIZIT and asked them<br />
for the smallest diameter available for CFRP<br />
cutters. By this point Piekenbrink Composite<br />
and CERATIZIT had a long-standing relation -<br />
ship dating back to 2015 and the mutual collaboration<br />
continued to expand as Piekenbrink’s<br />
use of CNC increased. “We were drilling more<br />
and more and milling meters of components.<br />
At the time, however, there were hardly any<br />
tools on the market that met our high-quality<br />
standards, while simultaneously offering acceptable<br />
service life. CERATIZIT tools were<br />
the exception – and a game changer in my<br />
view,” says Björn Piekenbrink.<br />
When machining CFRP/GFRP, cutting edges<br />
are crucial. “It’s really important that nothing<br />
becomes delaminated during the milling process,<br />
which means cutting the fibers correctly<br />
is key. This requires extremely sharp tools, but<br />
also reasonable service lives. Our MonsterMill<br />
FRP is designed to meet precisely these requirements,”<br />
says Lucas Wolf, the sales representative<br />
at CERATIZIT, responsible for managing<br />
Piekenbrink’s needs. As the materials<br />
are very abrasive, uncoated tools are no use<br />
here. Also the cutting edge needs to be treated<br />
accordingly. Especially extreme thin diamond<br />
coatings, only 9 - 12 µm thick, are ideal in<br />
these cases as they prevent the cutting edges<br />
From the equipment to the manufacture of CFRP laminates<br />
in various colors to the machining, Piekenbrink provides<br />
everything from a single source<br />
from being rounded off unnecessarily. “We always have to find a balance between<br />
the coating, the cutting edge, the service life and the cut finish,” adds<br />
Lucas Wolf.<br />
MonsterMill FRP: making light work of hard fibers<br />
Two separate sizes of the MonsterMill FRP were used to make the eyeglass<br />
frames: a 0 6.0 mm cutter from the standard range for milling and profiling,<br />
and a special 0 3.0 mm cutter. And a 0 1.0 mm MonsterMill milling cutter<br />
was also used to mill the temples. Marcel Klose, head of machining at<br />
Piekenbrink Composite GmbH, is delighted: “Since we started using the<br />
MonsterMill FRP with the new diamond coating, service lives have almost<br />
The MonsterMill FRP from CERATIZIT<br />
in its element: CFRP and GFRP are<br />
no match for the diamond-coated cutter,<br />
delivering clean cuts and long service lives<br />
An excellent cooperation:<br />
Björn Piekenbrink, managing director of Piekenbrink Composite GmbH,<br />
Marcel Klose, head of machining at Piekenbrink and<br />
Lucas Wolf, sales representative at CERATIZIT<br />
no. 2, May <strong>2023</strong><br />
7
cover story<br />
Marcel Klose:<br />
“Since we started using the MonsterMill FRP,<br />
service lives have almost doubled”<br />
doubled – and the cut is perfect. The benefit of having such a good cut lies<br />
in the fact that less reworking is needed for the final finish. As we achieve<br />
such a clean, sharp edge during machining, all it needs is a bit of deburring<br />
and then it’s done”. While it sounds minor, its impact is anything but, particularly<br />
when it comes to delicate components like those in carbon eyeglass<br />
frames.<br />
24/7 tool supply<br />
Although the MonsterMill FRP milling cutters<br />
offer exceptional service lives, it is still<br />
important to ensure optimal tool supplies<br />
at all times – also for all the other tools used.<br />
That is why Piekenbrink Composite uses the<br />
ToolOMat 840 from CERATIZIT. This tool<br />
procurement system for up to 840 different<br />
products is a high-tech dispensing system with<br />
IT integration. “Every employee in the relevant<br />
departments is assigned a chip that they<br />
can use to ‘procure’ their own tools during<br />
early or late shifts. This system has enabled us<br />
to achieve massive savings on storage. Plus we<br />
don’t have to take care of anything: tool supplies<br />
are always there and we only pay when<br />
the tool is actually used,” explains Marcel<br />
Klose. Daily tool stock management and the<br />
CERATIZIT replenishment service ensures<br />
that the ToolOMat always has the right tools<br />
and that they are available whenever they are<br />
needed.<br />
Björn Piekenbrink and Marcel Klose are<br />
also more than satisfied with the advice and<br />
service CERATIZIT provides. “Whenever we<br />
have a question or want to try out something<br />
new Lucas Wolf is always there to help. And it<br />
goes both ways: we test CERATIZIT tools and<br />
really put them to the test. We provide honest<br />
feedback on how they perform during a rigorous<br />
day of machining.”<br />
Piekenbrink deploys the MonsterMill series from CERATIZIT in 0 1.0 mm, 3.0 mm and 6.0 mm sizes<br />
further information: www.ceratizit.com<br />
8 no. 2, May <strong>2023</strong>
One milling cutter,<br />
full flexibility for all milling operations<br />
materials & tools<br />
Great tool flexibility is required when<br />
milling small and medium-sized<br />
production batches. The new<br />
EASYMill solid carbide endmill<br />
from LMT Tools combines<br />
maximum performance<br />
with universal applicability<br />
and sets standards in terms of<br />
process reliability, cost-effectiveness<br />
and user-friendliness. A real game<br />
changer for all common milling operations<br />
in ISO P1, P2 and M.<br />
LMT Tools stands for best product quality, unique solution<br />
expertise and technological innovations. The high performance<br />
tool solutions offer impressive performance as well<br />
as maximum process reliability.<br />
With the introduction of the new EASY product series<br />
LMT Tools expands its assortment with universally applicable<br />
plug-and-play tools that are characterized by maximum<br />
efficiency, great flexibility in application and ease<br />
of handling, and enable a significant reduction in process<br />
costs with optimum performance. The first product of<br />
the new EASY segment from LMT Tools is the EASYMill,<br />
a solid carbide milling cutter for the process-reliable machining<br />
of steel (e.g. case-hardened steels) and stainless<br />
steel materials (CrNi steels).<br />
Universal plug-and-play tool<br />
for all common milling operations<br />
The EASYMill features high stability as well as smooth<br />
milling operations with very good surface quality. Geome -<br />
try and coating have been specially adapted to the machining<br />
of low-alloy steels and austenitic materials and<br />
enable particularly flexible use. All common milling operations<br />
can be covered with just one tool – whether roughing,<br />
finishing, slot milling, ramping, pocket milling or<br />
helical plunging. The unequal helix pitch and positive<br />
cutting edge design reduce cutting pressure and cutting<br />
forces, resulting in a significant reduction in vibration. This<br />
also makes the EASYMill ideally suited for use on turning/milling<br />
machines. The adapted, sharp cutting edge ensures<br />
low build-up and guarantees smooth chip evacuation.<br />
A sticking of the chips and thus chip jams and tool breakage<br />
are prevented effectively. The EASYMill cuts up to the<br />
center and, thanks to the neck relief, enables infeed depths<br />
of up to three times the milling diameter.<br />
The new EASYMill solid<br />
carbide milling cutter from LMT Tools<br />
is a universal plug-and-play tool for all<br />
common milling operations in ISO P1, P2 and M<br />
and medium batch series as well as changing jobs. Even with<br />
lower-performance machines, it enables process-reliable and<br />
efficient milling. “The EASYMill is the result of an intensive<br />
analysis of customer requirements,” explains Marcus Paul,<br />
global head of product management at LMT Tools. “We want<br />
to make things as simple as possible for the customer and<br />
have developed a plug-and-play tool that is perfectly optimized<br />
for the application and meets the highest technological standards<br />
while offering significant cost benefits.”<br />
PRECISE. POWERFUL. PRODUCTIVE.<br />
kapp-niles.com<br />
further information: www.lmt-tools.com<br />
Best economy with optimum performance<br />
Excellent milling results, reduced process costs, universal<br />
application, uncomplicated handling: the EASYMill<br />
is the perfect symbiosis of top technology and economy.<br />
Optimized for best costs per milling meter, the new solid<br />
carbide milling cutter is particularly suitable for small
materials & tools<br />
Innovations at LIGNA <strong>2023</strong><br />
New tool concept based on the<br />
Fibonacci principle<br />
Users can benefit in a wide variety of ways from the<br />
tool innovations at LIGNA <strong>2023</strong>. For the first time at<br />
LIGNA, for example LEUCO will present the woodworking<br />
and processing industry with a completely<br />
new, patent-pending concept for arranging cutting<br />
edges on basic tool bodies. Another novelty at the<br />
show will be the regeneration of fixed slide milling<br />
cutters.<br />
The advantages of the various innovations are wide-ranging,<br />
be it reduced power consumption, longer tool life, better edge<br />
qualities or saving resources, etc..<br />
World premiere:<br />
The engineers at LEUCO were inspired by nature and successfully<br />
transferred the Fibonacci principle to the tool world<br />
for the arrangement and distribution of the cutting edges on<br />
the basic body. The Fibonacci principle can often be found in<br />
nature when it comes to the optimum utilization of limited<br />
space. Well-known examples are the seeds of a sunflower or<br />
a pine cone, whose number is maximally and optimally distributed<br />
on the available space. Arrangement of the blades<br />
according to the Fibonacci principle is patent pending by<br />
LEUCO. This approach from bionics enriches and expands<br />
the companies portfolio and is used where it achieves performance<br />
improvements.<br />
At LIGNA they will present the distribution of cutting<br />
edges on the basic body according to the Fibonacci principle<br />
using several tool types, including a Z4+4 nesting cutter<br />
with a 0 12 mm, the jointing cutters with exchangeable cutting<br />
blades “SmartJointer airFace” and the p-system, and a<br />
disk finger cutter. The benefits for customers vary per tool<br />
type: the range of advantages extends from lower power<br />
consumption and a finer cutting pattern to higher feed rates<br />
and longer tool life.<br />
10 no. 2, May <strong>2023</strong>
materials & tools<br />
Regeneration of diamond tipped cutter:<br />
According to the current state of the art in the industry,<br />
the life cycle of a diamond-tipped cutter ends as soon as<br />
the cutter can no longer be resharpened due to a too low<br />
tipping height. Exclusively for the two market-relevant<br />
diamond-tipped jointing cutters “DIAMAX airFace” and<br />
“DIAREX airFace”, a new technical process at the company<br />
allows the option of brazing out the worn cutting edges,<br />
brazing in new cutting edges and eroding them. In short<br />
the user virtually receives a new tool with the existing<br />
basic body. The cycle provides that once a “DIAMAX<br />
airFace” or “DIAREX airFace” jointing cutter has been purchased,<br />
it remains the property of the purchaser, who then<br />
orders the regeneration from LEUCO, thus starting a new life<br />
cycle with one and the same basic body. This regeneration<br />
can be carried out several times. The process will be available<br />
in Germany for the time being after LIGNA.<br />
Throughfeed machining:<br />
performance level increased for hoggers<br />
From hoggers machine operators expect above all very long<br />
tool lives. The previous PowerTec hogger is one of the most<br />
widespread hoggers on the market. At LIGNA <strong>2023</strong> the<br />
company will present the new generation with new cutting<br />
geometry called “Powertec 5 airFace” and demonstrably<br />
opens up a new performance class in terms of tool life. The<br />
unique diameter consistency of the “Powertec 5 airFace” provides<br />
users with exceptional ease of use. After resharpening,<br />
it’s “plug & play” because, thanks to this feature, the machine<br />
can continue to be operated with the machine parameters<br />
once set. The “PowerTec 5 airFace” hoggers are used for tearfree<br />
and low-noise formatting of raw, melamine resin and<br />
paper coated, HPL, foil covered and veneered wood-based<br />
materials from 8 mm board thickness, when tool life performance<br />
and cost-effectiveness are the decisive criteria.<br />
Machining on CNC:<br />
nesting with LEUCO “DIACURVE”<br />
shank-type cutters<br />
The special feature of this type of cutter at first glance is the<br />
arc-shaped or curved cutting edge shape and the unusual<br />
design of the diamond tablets. This design is a completely<br />
new manufacturing and milling concept.<br />
Each DP cutting edge has alternating axis angles, which<br />
ensure perfect cut quality in the surface layers. Instead of<br />
many small individual cutting edges, the continuous cutting<br />
edges and the large, continuous chip spaces enable a very<br />
good chip flow. Clogging of the peripheral cutting edges is<br />
effectively prevented.<br />
The new DIACURVE nesting cutters are currently available<br />
in five different dimensions. These variants are suitable<br />
for common wood-based materials. Each tool is designed<br />
for a specific panel thickness range. As a global supplier<br />
LEUCO is also familiar with the often very different market<br />
conditions in the various regions of the world as well as<br />
the resulting requirements in terms of price, technical prerequisites<br />
or even user-friendliness. DIACURVE nesting cutters<br />
cannot be resharpened, and the purchase prices are in<br />
the entry-level range. A new cutter is inserted after the end of<br />
DIACURVE nesting cutters with<br />
slim diameters and large chip volume<br />
The t3-System milling cutter family expands<br />
to include a copy router, drill, grooving cutter and<br />
socket milling cutter<br />
the tool life. Machine operators therefore do not have to enter<br />
(error-prone) settings of the parameters in the operating panels<br />
of the machines, but continue “plug & play” in their work.<br />
Solid wood machining:<br />
program expansion of LEUCO t3-system insert tools<br />
Four applications to its patent-pending t3-system insert milling<br />
cutter with the cambered triangular inserts are being added<br />
at LIGNA <strong>2023</strong>. The new products are designed as a nuter,<br />
copy cutter, drill and socket cutter. Like the t3-system end<br />
mill introduced in 2021, they show their strengths particularly<br />
in solid woods and wood-based materials. They achieve<br />
high-quality cuts on narrow sides, in rabbets lengthwise and<br />
crosswise to the grain, in free-form surfaces, and do so with<br />
high productivity.<br />
further information: www.leuco.com<br />
no. 2, May <strong>2023</strong><br />
11
materials & tools<br />
Focused<br />
Trends and innovations<br />
Leitz will be presenting its latest developments as<br />
an exhibitor at LIGNA in Hanover. This year the world<br />
market leader will be showing service concepts, industry<br />
focal points and trends from the furniture<br />
industry, structural timber engineering and advanced<br />
materials at its booth under the motto “Solutions in<br />
new dimensions”. The focus here is on the claim to<br />
further increase customer success.<br />
“Finding the optimally adapted solution for every requirement”<br />
– that is the daily incentive of the world market leader.<br />
Leitz sees itself as a solution provider whose products primarily<br />
support the increase in flexibility, efficiency and productivity<br />
of its customers in the relevant processes. With a total<br />
package of innovative tool technology, consulting, the constant<br />
exchange of information with all current machines and<br />
material manufacturers, as well as its fully comprehensive<br />
range of services, Leitz is the reliable partner for the wood<br />
and plastics processing industries all over the world.<br />
Focus on the furniture industry – forward-looking<br />
machining concepts for more flexibility<br />
and efficiency<br />
Manufacturing processes in the furniture industry are considered<br />
particularly complex. In some cases the industry has<br />
to meet the highest demands from consumers. Materials, surfaces<br />
and functionality, as well as different production philosophies,<br />
mean that the flow of daily challenges in manufacturing<br />
companies never stops.<br />
The NiRo Premium collet<br />
chuck made of stainless steel<br />
combines extremely high durability<br />
with great flexibility<br />
Leitz’s uniquely broad solution expertise ranges from panel<br />
sizing and trimming to edge finishing or drilling. Depending<br />
on the technical design of the process, whether using CNC<br />
machines or throughfeed machines, Leitz offers a tooling<br />
solution for every conceivable challenge. Leitz will be presenting<br />
a special highlight in Hanover with its new, innovative<br />
jointing concepts. They stand for maximum tool life,<br />
high process reliability and perfect machining quality –<br />
among other things with the help of the width-adjustable<br />
Diamaster EdgeExpert jointing cutter, which proves its durability<br />
every day. These are features that visitors to the<br />
LIGNA trade fair will be able to see for themselves in discussions<br />
with Leitz specialists.<br />
The EdgeExpert adjustable<br />
jointing cutters from<br />
Leitz are characterised<br />
by maximum precision,<br />
compact design and<br />
easy handling<br />
Focus on LeitzXPert – knowledge for your pocket<br />
Whether it’s the machine operator, the work preparation department<br />
or the foreman – in the individual processes in<br />
woodworking and plastics processing, questions about the<br />
tools used can arise again and again. In addition to the Leitz<br />
specialists, the LeitzXPert online application will also provide<br />
answers in the future. It contains tool expertise and information<br />
on almost all of the company’s standard products.<br />
Accessible free of charge the data are provided either via the<br />
LeitzXPert app or online via a browser-based Leitz knowledge<br />
platform. LeitzXPert was already presented as a study at<br />
LIGNA in 2019. In the meantime the application has completely<br />
outgrown its infancy and will be offered as a fullyfledged<br />
information platform in the future. Tool identification<br />
is very simple by entering the product ID number or via<br />
a QR or barcode. In addition to the product data from the<br />
Leitz Lexicon, the user is immediately offered additional<br />
product-related information, including videos. But that isn’t<br />
all. LeitzXPert also offers calculation programs for important<br />
application data in woodworking and plastics processing.<br />
Visitors to LIGNA can experience this new “knowledge for<br />
your pocket” in a hands-on way at the Leitz trade fair booth.<br />
Focus on CNC adaptors – competence<br />
in the field of tool adaptors<br />
Whether maximum flexibility through a quick tool change<br />
with the aid of a collet chuck or maximum precision through<br />
the use of a shrink fit chuck – Leitz will also be demonstrating<br />
its great expertise in the field of adaptors at this year’s<br />
LIGNA. The specialists from Oberkochen have the NiRo premium<br />
collet chuck made of stainless steel in their collection.<br />
An innovation that combines extremely high durability<br />
with great flexibility. A trapezoidal thread facilitates the<br />
transmission of force to the collet chuck, making it quicker<br />
and easier to mount shank tools. A ball-bearing ring also ensures<br />
that the tool does not rotate when tightening and thus<br />
provides the optimum hold for maximum precision during<br />
machining.<br />
further information: www.leitz.org<br />
12 no. 2, May <strong>2023</strong>
materials & tools<br />
Standard & custom coolant hole<br />
Configurations extend tool life<br />
The ability of the carbide cutting tools that you<br />
manufacture to dissipate the heat caused by friction<br />
is a critical part of your proprietary solution that you<br />
provide to your customers.<br />
Hyperion Materials & Technologies offers a wide range of<br />
standard and customizable coolant hole configurations to<br />
help you meet the specific performance and tool-life challenges<br />
of your customers. These configurations include:<br />
➢ central hole or parallel hole configurations<br />
➢ helical hole configurations<br />
➢ holes with lateral exit points ing<br />
With the ability to customize the carbide grade, number<br />
and shape of holes, coolant hole diameter, rod length, helix<br />
angle, finish and chamfer, Hyperion can provide you with the<br />
rod blanks that allow you to create the tools that set you apart<br />
from your competitors.<br />
further information: www.hyperionmt.com<br />
June 13-16, <strong>2023</strong>
materials & tools<br />
Nine cutting edges<br />
for higher metal removal rate<br />
Groove milling, cut-off milling or gear milling:<br />
these are just three milling processes that the circular<br />
interpolation milling system from Paul Horn GmbH<br />
carries out productively. As a true all-rounder, the<br />
extensive tool portfolio of this system tackles several<br />
other milling processes.<br />
It can be used from an inside 0 of 8 mm (0.315") for precise<br />
boring, for slot milling of narrow grooves down to a width<br />
of 0.25 mm (0.009"), or for milling splines: the system has<br />
proven to be a problem solver in numerous standard variants<br />
as well as in special designs for individual requirements.<br />
In order to further increase the chip removal volume during<br />
milling, Horn is expanding the circular milling system<br />
to include inserts with nine cutting edges. The smaller diameters<br />
of the system were previously available with a maximum<br />
of six cutting edges. Three more teeth offer further advantages.<br />
On one hand the production time is shortened due<br />
to the higher cutting feed rates that are possible, while on the<br />
other hand tool life is increased. In addition, the inserts run<br />
more quietly and with less vibration than inserts with fewer<br />
teeth. These advantages, in addition to the high milling<br />
performance of the tool system, contribute to higher overall<br />
efficiency and a reduction in tool costs.<br />
As a true all-rounder, the extensive tool portfolio of<br />
circular interpolation milling system from Horn tackles<br />
several other milling processes<br />
The new nine-edged milling systems M911, M913 and<br />
M928 are stocked in cutting widths from 1.5 mm (0.059") to<br />
3 mm (0.118") as standard. The maximum milling depth is<br />
3.5 mm (0.138") (M911), 4.5 mm (0.177") (M913) and 6.5 mm<br />
(0.256") (M928). The inserts are available with different coatings<br />
to suit the material to be machined. Due to its mass the<br />
solid carbide tool shank ensures vibration damping during<br />
milling. All variants of the tool shanks are equipped with<br />
an internal coolant supply.<br />
Horn is expanding the circular milling system with inserts that have nine teeth<br />
further information: www.horn-group.com<br />
14 no. 2, May <strong>2023</strong>
materials & tools<br />
Modular tooling system for high efficiency<br />
The modular system has a selection of tool holders for turrets and other tool carrier interfaces based on common machine types<br />
Thanks to its precision and rigidity, the modular<br />
tooling system from Paul Horn GmbH offers a high degree<br />
of flexibility for adaptation to different machine<br />
types. Standardized modules bridge several interfaces<br />
at the same time.<br />
The modular system has a selection of tool holders for turrets<br />
and other tool carrier interfaces based on common machine<br />
types. The matching grooving tool holders with integral coolant<br />
supply allow height adjustment of the cassettes and their<br />
mounting in the normal or overhead position, on the left<br />
or right side of the holder. For multi-spindle autos, height -<br />
adjustable tool carriers are available onto which the cassettes<br />
are directly screwed. The cassettes serve as an adapter<br />
for numerous Horn grooving insert systems. Parting off,<br />
grooving, sliding-head turning: the modular system can be<br />
flexibly adapted to the application.<br />
Horn is adding further variants to the modular system especially<br />
for use on Schütte machines. The type 850 tooling<br />
system supersedes the system 849. Of more compact size, the<br />
holder offers high stability as well as targeted cooling of the<br />
flank and rake face. The holder system is suitable for all sizes<br />
of the 315 insert system. For other inserts, HORN offers corresponding<br />
special solutions. The tool holders are available<br />
with and without angle adjustment. Height adjustment is<br />
simple and easily accessible from the front. The tool system is<br />
compatible with the Schütte series ECX, SCX and ACX.<br />
further information: www.horn-group.com<br />
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recycled-packaging-is-king
materials & tools<br />
Diamond coatings on cutting inserts:<br />
Alsameca special tools only with<br />
premium coatings from CemeCon<br />
Automotive, aerospace, medical technology<br />
– high-tech industries depend on first-class precision<br />
tools for the process-reliable, high-precision<br />
and, last but not least, economical production<br />
of their components from materials that are often<br />
difficult to machine. Alsameca from the French<br />
town of Lutterbach (Haut-Rhin) has made a name<br />
for itself in these industries with high-quality cutting<br />
tools. When it comes to finding solutions for<br />
special application, the company works closely<br />
with the coating expert CemeCon – for example in the<br />
field of diamond-coated cutting inserts.<br />
Anyone who enters Alsameca’s production facility is immediately<br />
struck by the ultra-modern machinery, in addition<br />
to the cleanliness and obvious love of order. Automated<br />
grinding centers, robot-controlled test benches, optimized<br />
production management – the manufacturer of precision tools<br />
and regrinding service spares no expense or effort to ensure<br />
the quality of its products and at the same time a rapid<br />
responsiveness. The goal is to “increase our productivity, gain<br />
market share and remain competitive,” says Pascal Guichard,<br />
founder and director of the ASP group, which includes<br />
Alsameca. For this he is constantly investing in automation<br />
and digital technologies. In 2008 Alsameca joined the ASP<br />
(Affûtage Service Performance) group with a total of 49 employees.<br />
ASP is known for its versatility in grinding and in<br />
the production of cutting tools and wear parts (solid carbide,<br />
brazed carbide or high-speed steel).<br />
Whether shank tools or cutting inserts – diamond coatings<br />
from CemeCon open up potentials in the machining of<br />
composites, graphite and non-ferrous metals<br />
Alsameca has been grinding precision tools for 42 years –<br />
today with 19 employees around 140,000 tools annually – and<br />
has designed many sophisticated solutions for a wide range of<br />
industries. The experts know exactly how important the interaction<br />
of substrate, cutting-edge geometry and coating is.<br />
ASP has its own PVD coating expertise in-house and uses it<br />
successfully mainly for standard tools. Precision tools for special<br />
applications, for first-class premium coatings, Alsameca<br />
additionally relies on the experience of CemeCon.<br />
Stéphane Kalt,<br />
Director of Alsameca:<br />
“With CemeCon’s<br />
diamond coatings, for<br />
example, we have been<br />
able to signifi cantly<br />
increase the<br />
performance of our<br />
cutting inserts – both<br />
in terms of tool life and<br />
machining quality.”<br />
Machining lightweight materials<br />
with diamond-coated cutting inserts<br />
Alsameca cutting inserts score with exceptional cutting-edge<br />
geometries, multi blade configuration and high feed rates.<br />
“With their nanocrystalline, extremely smooth and hard<br />
surfaces, our CCDia® coatings are superior to other coating<br />
solutions in terms of performance, quality and precision and<br />
contribute significantly to even higher efficiency. Especially<br />
on cutting inserts for machining CFRP and GFRP, graphite,<br />
non-ferrous metals or plastics, CCDia® coatings open up<br />
enormous potentials,” says Jean Cariolini, sales Europe at<br />
CemeCon. The powerful combination of Alsameca’s cutting<br />
inserts and CemeCon’s diamond coatings achieves excellent<br />
results when machining lightweight materials for the automotive<br />
and aerospace industries.<br />
Matching all the parameters in a joint engineering approach<br />
of CemeCon and Alsameca made this happen. The experts<br />
coordinate the coating precisely with the requirements<br />
and application in a close dialogue. Substrate, geometry<br />
and coating all together form an optimal machining solution<br />
for the respective application – perfect for Alsameca’s sophisticated<br />
tool concepts and special applications.<br />
Service life significantly increased<br />
Stéphane Kalt, director of Alsameca: “Whether dedicated<br />
diamond coatings for our cutting inserts or high-performance<br />
HiPIMS coatings for special applications – we have<br />
already worked with CemeCon in many successful engineering<br />
projects and are always very satisfied with the results and<br />
with the speed of implementation. With CemeCon’s diamond<br />
coatings, for example, we have been able to significantly<br />
increase the performance of our cutting inserts – both in<br />
terms of tool life and machining quality.”<br />
further information: www.cemecon.com<br />
16 no. 2, May <strong>2023</strong>
CBN grinding discs for highest quality requirements<br />
Small, but powerful<br />
materials & tools<br />
Small CBN grinding discs<br />
25 millimeters – the size of a two-Euro coin – is the<br />
diameter of the new CBN grinding discs developed<br />
by Liebherr-Verzahntechnik GmbH specifically for<br />
machining critical component geometries with low<br />
tool overrun. They can be coated with specifically selected<br />
grain for longer service life and faster grinding<br />
processes.<br />
Alongside diamond, CBN (cubic crystalline boron nitride) is<br />
one of the hardest grinding materials available. CBN grinding<br />
discs are suitable for the highest quality requirements<br />
because they are dressing-free, wear-resistant and heat-resistant.<br />
Liebherr has developed very small CBN grinding discs<br />
with a diameter of just 25 millimeters for gears subject to<br />
collision and with low tool overrun. The company is therefor<br />
extending the geometric process limits for internal and external<br />
gears with interfering contours.<br />
CBN expertise at Liebherr<br />
CBN grinding discs have a steel body which is electro- plated<br />
with abrasive CBN grains. The basic steel body is breakresistant<br />
and can be reused several times. However, the<br />
manu facturing process is complex, especially when making<br />
very small discs. With more than 30 years of CBN expertise,<br />
Liebherr has the necessary know-how to manufacture the<br />
grinding discs completely in-house.<br />
Optimized design<br />
The smaller the discs, the more complicated they are to<br />
manu facture: “In this size range the process has no margin<br />
for error,” explains Haider Arroum, head of sales for gear<br />
cutting tools at Liebherr. “And you also have to choose the<br />
right grain size to achieve the desired surface roughness of<br />
the workpiece while generating as little wear as possible, even<br />
at high rotary and cutting speeds.” Liebherr’s special design<br />
allows for shorter and more economical grinding processes.<br />
Successful in the aerospace industry<br />
The tiny discs are already being successfully used by<br />
Liebherr-Aerospace for profile grinding of small gears for<br />
planetary gear trains. “They’re very happy with the results.<br />
And as expected, both the quality and the cost-effectiveness<br />
were excellent – an important factor in this area in particular,”<br />
says Haider Arroum.<br />
further information: www.liebherr.com<br />
no. 2, May <strong>2023</strong><br />
17
materials & tools<br />
Boehlerit – the independent development partner<br />
for toolmaker<br />
Since 1932 Boehlerit has been a pioneer in the<br />
production of carbide. Today the standard portfolio<br />
includes more than 70 cutting-edge carbide grades,<br />
which are used by almost all well-known toolmakers<br />
for a wide range of applications. In addition as a development<br />
partner for toolmakers, the company from<br />
Kapfenberg with its decades of experience, offers the<br />
development of individual carbide grades, coatings<br />
and geometries. In this way real machining innovation<br />
often begins in Boehlerit’s own powder production.<br />
Compared to the past, modern carbides are characterised<br />
by more uniform microstructures. This is primarily due to<br />
the higher purity of the raw materials, but above all also to<br />
more uniform sintering conditions in modern production<br />
facilities.<br />
High metallurgical flexibility for<br />
individual tool developments<br />
Boehlerit’s metallurgy center, with its own powder production,<br />
has for decades been the hub for the development of innovative<br />
cutting materials. Over 10,000 m 2 of production<br />
space offer maximum metallurgical flexibility for the production<br />
of indexable inserts and blanks as well as for the provision<br />
of carbide granulate for toolmakers. The dynamic FEM<br />
calculation for the digital customer-specific design of modern<br />
tool systems is supportive here.<br />
Boehlerit is an independent carbide specialist in the tool<br />
industry and a close development partner for toolmaker.<br />
In its cooperation with toolmakers, the family-run company<br />
guarantees direct collaboration between technologists with<br />
discretion and product protection. “When you work as a<br />
long-term partner with almost all well-known tool manufacturers,<br />
trust is the order of the day”, emphasises Dr.<br />
Christian Kolbeck, head of segment wear parts & toolmaker.<br />
However Boehlerit is not only a technological pioneer and<br />
one of the world’s leading manufacturers of carbide cutting<br />
materials for tools used in metal, wood and plastics processing,<br />
but also ethical. Only carbides made exclusively from<br />
conflict-free raw materials are produced. This ethically justifiable<br />
procurement of materials and raw materials has been<br />
one of the pioneering elements of the company’s compliance<br />
culture for many years.<br />
State-of-the-art production and coating processes<br />
The continuous development of production processes using<br />
state-of-the-art production equipment plays a major role in<br />
the carbide expertise. This includes the latest servo-electric<br />
powder presses, which offer the highest reproducibility and<br />
dimensional accuracy and enable the production of highly<br />
complex geometries.<br />
Dr. Christian Kolbeck,<br />
head of segment wear parts & toolmaker<br />
A special feature among the presses at Boehlerit is one of<br />
the largest carbide presses with a pressing force of 650 t.<br />
Cubic and round parts with a surface area of up to 250 cm 2<br />
are pressed economically and in series production on this<br />
press. All in all the production range extends from the smallest<br />
carbide part weighing a few tenths of a gram to large parts<br />
weighing more than 100 kg. The tools for this are made in the<br />
company’s own press tool shop. This guarantees μm-precise<br />
18 no. 2, May <strong>2023</strong>
materials & tools<br />
Boehlerit procured a new 5-axis hard milling<br />
machine, which now performs milling, grinding<br />
and testing in one clamping and replaces<br />
the EDM technology previously used for this<br />
purpose in this area. Particularly in coating<br />
technology – one of the company’s core compe -<br />
tences – investments are naturally made on an<br />
ongoing basis. In addition to the latest PVD<br />
technology (HiPIMS), Boehlerit is expanding<br />
its CVD plant park with a new coating plant<br />
equipped with its own innovations. Boehlerit<br />
uses its expertise in coating technology and<br />
thus has the entire process in its own hands.<br />
This is one of the reasons for the company’s<br />
technological lead and offers new possibilities<br />
with regard to the deposition of innovative<br />
hard material coatings.<br />
One of the world’s most modern 4.0 RAM<br />
extruders, a new double-sided fine grinding<br />
machine with planetary kinematics, new<br />
clean ing and washing systems and new simula<br />
tion software, which, for example, examines<br />
chip formation and chip flow even before the<br />
step into the cutting laboratory, finalize the<br />
investment programme. All the new systems<br />
are networked with each other. Sustainability<br />
and energy efficiency have long been at the top<br />
of Boehlerit’s agenda of course. Especially in<br />
times of energy crisis, these investments are<br />
particularly effective in many respects.<br />
Boehlerit – the independent development partner for toolmaker<br />
tools with which complex indexable inserts are precision-manufactured.<br />
“Our hand shaping department requires very special know-how, and we use<br />
it to produce more than 7,000 different types of carbide parts every year”,<br />
Kolbeck adds. Here the constructive shaping, taking into account the socalled<br />
sintering shrinkage, requires a great deal of experience. In addition to<br />
sintering, Boehlerit’s know-how is based on its own coating center. The main<br />
coating technologies (PVD, HT-CVD and MT-CVD) for hard material coating<br />
of indexable inserts are available.<br />
State-of-the-art production machines guarantee<br />
the highest quality<br />
As part of its quality and automation offensive, Boehlerit has decided on a<br />
comprehensive investment package that specifically addresses the three decisive<br />
factors of its products – substrate, cutting edge finishing and coating. Four<br />
new high-end sintering systems (three pressure sintering systems and one<br />
vacuum sintering system) were purchased, as well as a large 5-axis turning/<br />
milling machine on which preforms are produced. In addition six new grinding<br />
machines for inserts ensure a long-term guarantee of the high quality<br />
level. Boehlerit produces around 150 to 200 pressing tools made of sintered<br />
carbides per year for customers, but also for its own needs. For this purpose<br />
From powder to rapid prototyping<br />
to cutting tests<br />
The development tasks of the carbide pioneers<br />
at Boehlerit are defined respectively by the<br />
performance requirements of the tool manufacturers<br />
and users. Process-optimised manufacturing<br />
technologies, from its own powder<br />
production, coupled with the latest pressing<br />
and grinding technologies to the most modern<br />
coating technologies, guarantee toolmakers<br />
a head start in the productivity of their<br />
tools time and time again. A particular advantage<br />
in product development for toolmakers<br />
is the production of prototypes using<br />
state-of-the-art laser-assisted rapid prototyping.<br />
Boehlerit thus helps customers to save<br />
time and money in tool development. This<br />
also includes cutting tests, evaluation and<br />
advice. Finally one of the most modern testing<br />
and packaging systems for indexable inserts<br />
in the industry contributes to the high quality<br />
standard. It guarantees 100 % quality assurance<br />
in the μm range. With particularly strict<br />
dimensional checks and the monitoring of all<br />
metallurgical parameters, Boehlerit guarantees<br />
toolmaker a consistently high quality of<br />
its tools.<br />
further information: www.boehlerit.com<br />
no. 2, May <strong>2023</strong><br />
19
materials & tools<br />
A premium solution<br />
for hot mill roll grinding<br />
Designed with the increasingly competitive steel<br />
market landscape, 3M introduces its new premium roll<br />
grinding solution: a wheel that cuts faster, lasts longer,<br />
runs cooler and achieves substantial cost savings and<br />
productivity improvements.<br />
The 3M solution was built to meet the extreme challenges of<br />
narrow and tighter profile tolerances along with finer surface<br />
roughness expectations. Moreover, the total absence of defects<br />
such as feedlines or scratches require adapted grinding<br />
solutions. Compared to conventional wheels, 3M Cubitron II<br />
resin bond grinding wheels 92BC can complete up to 30 %<br />
more rolls. Longer-lasting performance is combined with up<br />
to a 20 % faster cut and 30 % lower cycle time than standard<br />
grinding wheels.<br />
Grinding wheels 92BC<br />
built to meet the<br />
extreme challenges of<br />
narrow and tighter profile<br />
tolerances along with<br />
finer surface roughness<br />
expectations<br />
3M considered several key market trends when designing<br />
its new grinding wheel such as process optimization, process<br />
efficiency, harder materials to grind as well as the increasingly<br />
more demanding quality standards required. Increasing<br />
grinding wheels’ durability and overall grinding performances<br />
is how the new 3M Cubitron II resin bond grinding<br />
wheels 92BC helps to achieve the industry’s costs savings targets.<br />
The new grinding wheels, additionally, free up capacity<br />
while helping to reduce overall grinding times.<br />
The most suitable grinding wheel specification will depend<br />
on the composition of the rolls. The content of chromium and<br />
other alloying elements is an important factor when selecting<br />
a grinding wheel’s specification. Generally the carbide-forming<br />
elements which generate these hard carbides in high alloyed<br />
steels, contribute strongly to how hard the specific steel<br />
grade is to grind. The harder the steel, the better the new 3M<br />
Cubitron II resin bond grinding wheel 92BC outperforms<br />
other conventional solutions.<br />
100 µm<br />
3M precision-shaped<br />
grains made with<br />
3M micro-replication<br />
technology enabling<br />
a more efficient<br />
grinding solution<br />
3M precision-shaped grains<br />
Conventional grains tend to grind through the metal causing<br />
heat to build up in the workpiece and the abrasive, resulting<br />
in a slower cut with a shorter lifetime. Whereas the unique<br />
3M precision-shaped grains made with 3M micro-replication<br />
technology, continuously form sharp peaks that easily slice<br />
through metal, thus cutting cooler, faster and lasting longer<br />
than conventional grains. 3M precision-shaped grains can<br />
now be oriented into a specific direction, thereby optimizing<br />
the usage of each single oriented grain. With the new 3M<br />
Cubitron II resin bond grinding wheels 92BC, 3M observed<br />
that grains stacking into a specific zone is far reduced thus<br />
preventing mineral agglomeration and notably reach better<br />
grains anchorage into the bonding system.<br />
New resin bond formulation with homogeneous pores forming<br />
and distribution drastically improves the overall cooling system<br />
resulting in substantial positive impact on performance<br />
New resin bond formulation<br />
Having a more homogenously distributed pore structure<br />
helps to drastically improve the overall cooling system since<br />
the entire wheel’s thickness is instantly flooded by the cooling<br />
fluid being captured by the wheel’s opened structure. Even<br />
in extreme stock removal conditions, it does facilitate chips<br />
evacuation outside of the contact area preventing from generating<br />
heat which may lead to thermal damages. The grinding<br />
process runs cooler with substantial positive impact such as<br />
wheel’s durability extension and work parts quality improvements<br />
(free of burning marks). Finest surface roughness (Ra):<br />
down to 0.3 - 0.5 µm is easily achieved and maintained.<br />
further information: www.3M.com<br />
20 no. 2, May <strong>2023</strong>
materials & tools<br />
Four inserts for stator bores<br />
Actuating tools are the means of choice for creating turning<br />
geometries on machining centers. When it comes to machining<br />
stator bores on electric motors, tools with indexable inserts and fine<br />
boring tools were considered the state of the art until now. MAPAL<br />
has developed a complex four-bladed actuating tool to round off<br />
its solution portfolio for stator drilling.<br />
With its Expert Solution, MAPAL has come up with a highly productive<br />
machining process for the series production of stator housings for electric<br />
motors. The solution offers productivity and precision as well as short<br />
cycle times with a process of three steps: pre-machining, semi-finishing and<br />
fine machining at machining diameters of more than 220 mm and with an<br />
HSK100 connection. A sophisticated actuating tool is part of the solution.<br />
“With an actuating tool the internal machining of the bore can be handled<br />
by a machining center, which means turning is no longer necessary”, says<br />
Oliver Müller, customer service specialist at the MAPAL Centre of Competence<br />
for Actuating Tools. The entire machining process can thus be executed<br />
with a single clamping setup. The only thing needed to use the actuating tool<br />
is a spindle with a drawbar – a so-called U-axis in the machining center.<br />
“When it came to machining parts for electric cars we were at our customers’<br />
side with our tools from the very beginning. Today we help them to<br />
increase flexibility while machining the parts reliably and with short cycle<br />
times”, Müller explains. The actuating tool achieves more flexibility by<br />
ensuring both fast machining of varying contour trains in the bore as well<br />
as precision down to the micrometer.<br />
For example a thin-walled stator housing with a 220 mm stator bore is machined<br />
on a machining center with an HSK100 connection. “The machining<br />
of the stator bore with indexable insert tools and fine boring tools represents<br />
the state of the art. They have proven themselves over and over again.<br />
However, to achieve more flexibility for faster machining, we developed a<br />
tool with four slides together with machine manufacturers and customers”,<br />
Müller says. The drawbar controls four facing slides equipped with ISO<br />
inserts and handles both pre-machining and fine machining. PCD cutting<br />
edges are used as the housing is made of aluminium. After the machining<br />
is done, the inserts are retracted, and the tool is moved out of the housing<br />
via rapid traverse. This saves cycle time without the risk of damage to the<br />
new surface. This solution is particularly productive and focusses on high<br />
quality, which is why it has found its way into the Expert Solution range of<br />
MAPAL’s solution portfolio.<br />
Each of the four slides of the 22.5 kg heavy tool has a face stroke of<br />
20 mm – the inserts can thus be extended to 0 40 mm. The drawbar compensates<br />
for wear and tear directly during machining. This makes for particularly<br />
reliable machining. For even shorter cycle times, the actuating tool is designed<br />
as a combination tool. In addition to machining the stator bore, steel<br />
bushings are pre-machined with four carbide inserts.<br />
“The tolerance of the large bores is set to IT6 quality. That shows the precision<br />
with which our tools are manufactured, assembled and set. The four inserts<br />
have to interact with micrometer precision”, Müller states.<br />
The actuating tool with<br />
four cutting edges stands for<br />
high process reliability and flexibility<br />
during the machining of stator bores<br />
And so the experienced workers at the<br />
MAPAL Centre of Competence know the actuating<br />
tool inside out. Müller explains: “Assembling<br />
this sophisticated tool is similar to<br />
watchmaking.” It takes two to four weeks to<br />
assemble one tool. In order to set up the tool<br />
precisely at the customers’ premises, MAPAL<br />
offers a suitable setting device. The special<br />
machine is based on the UNISET-V and<br />
equipped with an additional axis – like the<br />
machining center.<br />
Cutting data:<br />
▶ aluminium machining<br />
v c = 690 m/min<br />
f z = 0.20 mm (pre-machining)<br />
f z = 0.15 mm (fine machining)<br />
spindle speed = 1000 rpm<br />
▶ steel machining<br />
v c = 160 m/min<br />
f z = 0.16 mm<br />
spindle speed = 690 rpm<br />
Not only the cutting data (see box) and the<br />
resulting surfaces with an Rz < 6.3 µm convince<br />
on the shop floor, the tool life of the inserts<br />
also does. The PCD inserts can machine<br />
3,600 parts before being changed. The carbide<br />
inserts manage 600 parts. “Our customers are<br />
very happy with the tools”, Müller relates.<br />
“The housings continue to be further developed;<br />
the contours slightly adapted. Thanks to<br />
the actuating tool, we can react to this easily<br />
and without changing the tool.”<br />
further information: www.mapal.com<br />
no. 2, May <strong>2023</strong><br />
21
news & facts<br />
Fiscal year 2022 –<br />
Fritz Studer AG<br />
At this year’s press conference of Fritz Studer AG, CEO<br />
Jens Bleher welcomes the press representatives to a historic<br />
site: “Exactly 111 years ago Fritz Studer founded<br />
his company here in Steffisburg. Since then the pioneer<br />
in cylindrical grinding has presented countless technological<br />
innovations – a long tradition that is our obligation<br />
for the future.”<br />
We are therefore particularly pleased that STUDER succeeded<br />
in continuing its growth course in 2022 and significantly increase<br />
sales. Bleher is thus also very positive about the outlook<br />
for <strong>2023</strong>: “After a remarkable final spurt at the end of the<br />
year, STUDER started <strong>2023</strong> in full momentum, with a large<br />
order backlog.”<br />
Positive development of the order situation<br />
“Overall it was the third-best year in our company history in<br />
order intake,” says CSO Sandro Bottazzo. Expectations were<br />
exceeded by far in all sales regions. Some countries, such as<br />
Turkey, even recorded the highest order intake in company<br />
history. As a global manufacturer of high-precision grinding<br />
machines, STUDER is worldwide active. “All in all, in<br />
2022 we once again succeeded in expanding our position in<br />
the most important markets in the world and increasing our<br />
market share,” summarized Bottazzo.<br />
In 2022 almost all markets showed growth in orders. New<br />
customers made 37 % of the orders. Furthermore, the secondbest<br />
individual month in the history was December. The aerospace<br />
and energy segments contributed to this positive development<br />
significantly. The tooling, die and mold, and machine<br />
manufacturing segments remained stable at a very high<br />
level. The precision engineering segment with the small and<br />
medium-sized supplier companies and contract manufacturers<br />
remains the largest individual segment. In the automotive<br />
sector on the other hand was a decline, which specifically<br />
affected demand for production machines. “However, our<br />
good positioning and broad portfolio are helping us greatly,”<br />
emphasizes Bottazzo.<br />
Broad portfolio as key to success<br />
A broad portfolio that can fulfill a wide variety of customer<br />
requirements is both our trademark and an important pillar<br />
for STUDER’s success. In the 2022 business year universal<br />
and internal cylindrical grinding machines showed a positive<br />
trend, in both the standard and system business. The bestseller<br />
among the STUDER machines was once again the versatile<br />
S33 CNC universal cylindrical grinding machine, which<br />
is capable of producing small and large workpieces in both<br />
single and series production. Other machines that sold very<br />
well were the favorit, the S31 and the S41. In the sales of internal<br />
cylindrical grinding machines, STUDER achieved its<br />
second-best annual result ever. Another area that reached a<br />
record high was the WireDress® technology, which enables<br />
the precise dressing of metal-bonded grinding wheels possible<br />
and thus boosts productivity to extremely high levels.<br />
Stephan Stoll - COO, Jens Bleher - CEO, Sandro Bottazzo - CSO<br />
and Daniel Huber - CTO (beginning left)<br />
Customer care with record sales<br />
Bottazzo has more good news from the area of customer<br />
care. Here STUDER achieved a new revenue record in 2022.<br />
STUDER has further expanded its service organization because<br />
of good business developments. Customers profit from<br />
even better availability and faster problem-solving, numerous<br />
business processes have been digitized and optimized.<br />
Development of numerous new products<br />
The 2022 business year also brought numerous new developments<br />
and an expanded product range. “With our product offensive,<br />
innovative and application-specific solutions, we can<br />
even better address the needs of our customers,” says Daniel<br />
Huber, CTO at STUDER. On the China market, on the one<br />
hand, the new generation of the well-proven KC33 CNC universal<br />
cylindrical grinding machine was presented. On the<br />
other hand Chinese customers now have, with the ecoGrinder,<br />
an economical entry-level solution available – and it has already<br />
found numerous buyers. “In 2022 we presented an innovation<br />
at almost every large trade show,” says Huber. This<br />
includes the S36 production machine at GrindingHub in<br />
Stuttgart. It closes a gap in the portfolio between the S11 and<br />
S22 and is particularly well-suited to applications and components<br />
in the field of electromobility. Now the S36 is also<br />
available with an innovative energy monitoring concept. Or<br />
there’s the new S100 that was presented at the BIMU in Milan,<br />
a perfect entry-level option in the field of CNC universal internal<br />
cylindrical grinding machines.<br />
Investment in the future<br />
Regular and systematic investments in all areas of the company<br />
are part of STUDER’s company philosophy. “We are<br />
con vinced that this will keep our locations competitive and<br />
that Studer machines ‘Made in Switzerland’ will have a strong<br />
foothold on the world market in the long term,” explains Stoll.<br />
Following the redesign and modernization of assembly, the<br />
focus was on manufacturing over the past few years. In 2022<br />
several projects contributed to ensuring that the production<br />
resources remain state-of-the-art, with a special focus on<br />
automation and digitization. In the coming year spindle shaft<br />
production will be renewed and expanded, and the warehouse<br />
and logistics infrastructure comprehensively modernized<br />
by 2025.<br />
further information: www.studer.com<br />
22 no. 2, May <strong>2023</strong>
news & facts<br />
New location in Thailand<br />
From April <strong>2023</strong>, the Horn Group will have a subsidiary<br />
in Thailand. Horn Cutting Tools (Thailand) Co.<br />
Ltd. will have its headquarters in Chonburi – approximately<br />
80 km (49.7 miles) south-east of Bangkok, the<br />
capital of the Kingdom of Thailand.<br />
The company will commence operations with six employees.<br />
In the short to medium term, a regrinding service for MCD<br />
tools will be set up in addition to the sales department.<br />
Horn Thailand will be exhibiting at Metalex in Bangkok,<br />
November 22 nd – 25 th , <strong>2023</strong>. On display will be Horn’s <strong>2023</strong><br />
innovations and various tooling solutions such as Supermini,<br />
gear cutting, reaming and grooving. 2022 more than 86,000<br />
trade fair visitors came to Metalex. In addition to domestic<br />
visitors, people came primarily from India and Singapore.<br />
Concerning trends and future issues in Thailand, Andreas<br />
Vollmer, member of the management board at HORN and<br />
responsible for worldwide sales said: “What we have seen so<br />
far and the discussions we had during the Metalex exhibition<br />
in Bangkok last year show that machining strategies are<br />
identical to existing customer requirements that we are already<br />
familiar with, not only in Thailand but also in Vietnam<br />
Singapore, Indonesia, Malaysia and the Philippines. The topic<br />
of gear cutting is already a live discussion.”<br />
The Horn Thailand Team is very well prepared for the tasks<br />
ahead. Technical product training will take place in the new<br />
offices in order to pass on a high level of technical expertise to<br />
customers. Horn Thailand will also have a warehouse on-site<br />
to serve the Southeast Asian market to ensure quicker and<br />
safer deliveries.<br />
further information: www.horn-group.com<br />
The Horn Thailand team: Uten Tonsirach/production,<br />
Michael Mellerup/general manager,<br />
Jakapat Udomporn/national sales manager (beginning left)<br />
The company headquarters of<br />
Horn Cutting Tools (Thailand) Co. Ltd. in Chonburi<br />
with a total area of approx. 1,250 m 2<br />
New representation in Denmark<br />
MAPAL extends the long-standing partnership with Edeco Tool<br />
Since February 1, <strong>2023</strong>, Edeco Tool ApS has been the<br />
official sales representation of MAPAL in Denmark.<br />
The company is already a long-standing partner and<br />
has been working successfully with various centers of<br />
competence of the MAPAL Group.<br />
Due to these good relationships the management of MAPAL<br />
decided to give Edeco Tool ApS the official representation for<br />
Denmark.<br />
Armin Kasper, vice president sales: “We are pleased to<br />
have found a well-established partner with Edeco Tool ApS.<br />
Due to its organisational structure as well as its technically<br />
experienced staff, we can ensure the best possible support<br />
for our customers in Denmark. We are confident that this<br />
change will be well received by the market.”<br />
The team in Denmark knows MAPAL’s range of products<br />
and services. They are specialists who understand the customers’<br />
requirements and bring considerable experience to<br />
the extended cooperation. Edeco is active in various areas of<br />
industry. The company serves customers in the automotive<br />
and mechanical engineering sectors, as well as die and mould<br />
making, the energy sector and the aerospace industry.<br />
The trading company, which serves customers in Denmark<br />
and Sweden, operates a central warehouse in Swedish Karlstad.<br />
This ensures that also the customers in Denmark receive<br />
standard products quickly and reliably. Edeco Tool ApS is<br />
based in Glostrup near Copenhagen, a regional office is also<br />
located in Thisted and serves customers from Jutland. A wide<br />
range of MAPAL tools is available at the Edeco Webshop.<br />
further information: www.mapal.com<br />
no. 2, May <strong>2023</strong><br />
23
news & facts<br />
Vollmer appoint new UK managing director<br />
VOLLMER has now appointed Martyn Cross as the new managing<br />
director of the VOLLMER UK subsidiary. Working alongside longstanding<br />
managing director Peter Allen in the interim, Martyn has<br />
joined VOLLMER UK to build upon the strong growth already overseen<br />
by Peter Allen over the last 24 years.<br />
Since the end of 2012 Peter Allen has filled two roles as both managing director<br />
of VOLLMER UK and president of VOLLMER of America. With the<br />
recent construction of a new facility at VOLLMER of America and the high<br />
demand for technologically advanced solutions in the UK as well as the USA,<br />
Canada and Mexico, Peter has decided to fully focus on the exceptional potential<br />
of the North American marketplace. With Martyn Cross joining the<br />
VOLLMER UK team, the company will have a dedicated managing director<br />
with decades of expertise in the cutting tool manufacturing sector.<br />
Martyn served a mechanical apprenticeship in the 1970’s and has progressed<br />
his career from apprentice to applications engineer, on to positions as<br />
technical sales manager, production manager and subsequently director with<br />
many of the world’s leading tool and cutter grinding machine tool manu -<br />
facturers. Such is the expertise of Martyn; he has also spent time working as<br />
an R&D manager at a prominent UK cutting tool manufacturer.<br />
Upon Martyn’s appointment, joint managing director at VOLLMER UK,<br />
Peter Allen says: “We are delighted to appoint an engineer, manager and<br />
leader of Martyn’s caliber. Martyn’s industry knowledge, insights and reputation<br />
precede him. The experience that Martyn will bring to VOLLMER UK<br />
is second to none and his unfathomable relationships within the industry<br />
will certainly help to further enhance the position of VOLLMER in the UK.”<br />
“The VOLLMER brand is growing exponentially with the launch of a completely<br />
new suite of machine tools launched at GrindingHub last year. Not<br />
only is VOLLMER a full-line manufacturer of grinding, erosion and laser<br />
machine tools with a growing portfolio, but we have also introduced new<br />
brands and technologies to the group such as the ultraTEC ultrasonic deburring<br />
systems. To attentively support our customers in the UK and North<br />
America with the growing range of machine solutions, I have made the conscious<br />
decision after a lot of hard commitment to both subsidiaries, to gradually<br />
step away from the UK business and focus on the next chapter of my<br />
career with VOLLMER of America.”<br />
Peter Allen (left) hands over his position<br />
as managing director of Vollmer UK to<br />
Martyn Cross<br />
“After serving as the UK managing director<br />
for more than 18 years there will be a transition<br />
period where I will be introducing Martyn<br />
to our internal and external teams, our company<br />
structures and to many of our prestigious<br />
UK customers. I have little doubt<br />
that Martyn will build upon the growth the<br />
VOLLMER UK team is delivering and drive<br />
the company forward.”<br />
further information: www.vollmer-group.com<br />
GEFERTEC now wholly owned by the<br />
Berlin.Industrial.Group<br />
Effective immediately, B.I.G. Holding is the sole owner of<br />
GEFERTEC. In a joint decision with founding partners Tobias<br />
Röhrich and Georg Fischer, the Group has acquired their shares.<br />
B.I.G. Holding had already purchased the shares of EMAG (10 %) in<br />
June last year.<br />
“This gives GEFERTEC the necessary freedom of action to further expand<br />
and solidify its position in the growing market for 3D metal printing,” says<br />
Igor Haschke, managing director of GEFERTEC and owner of the Berlin.Industrial.Group.<br />
(B.I.G.).<br />
Demand for these machines is rising, particularly in the USA. GEFERTEC<br />
offers complete manufacturing systems for metal 3D printing in the<br />
Wire-Arc-Additive-Manufacturing (WAAM)<br />
process. Therefore the traditional gas metal<br />
arc welding is combined with special process<br />
expertise for the additive manufacturing<br />
of components, a robust machine system, integrative<br />
CAM software and process-related<br />
quality assurance. The robust process, high<br />
build rates and ease of handling wire as a<br />
feed stock make the process interesting for<br />
manufacturing medium to large components.<br />
further information: www.gefertec.de<br />
24 no. 2, May <strong>2023</strong>
fairs<br />
news & facts<br />
EMO Hannover <strong>2023</strong> focuses on current production technologies<br />
Joint booths keep production experts up to date<br />
Want to learn about the latest in production technology?<br />
Production experts to EMO Hannover <strong>2023</strong><br />
will be doing just this in September. They can experience<br />
live and on site the latest trends at a total of four<br />
joint booths. These booths will be focusing on additive<br />
manufacturing, connectivity, open space cobot solutions<br />
and sustainability.<br />
Martin Göbel, director exhibitions at the EMO organizer<br />
VDW (Verein Deutscher Werkzeugmaschinenfabriken, or<br />
German Machine Tool Builders’ Association) in Frankfurt am<br />
Main, knows the value of a visit: “Nowhere else can production<br />
specialists experience the sector’s innovations so close<br />
up – presented in thematic packages over the entire process<br />
chain, and up to date at all times. So if you’re coming to EMO<br />
Hannover <strong>2023</strong> in September, you shouldn’t miss out on the<br />
joint booths.”<br />
Innovative 3D printing as a fixed constituent<br />
No matter whether aircraft construction, medical engineering,<br />
or hydrogen economy – additive manufacturing methods<br />
are growing in importance in production. And the business<br />
prospects are good: this was verified recently by a survey<br />
among the approx. 200 member companies of the Additive<br />
Manufacturing Working Group within the VDMA (Verband<br />
Deutscher Maschinen- und Anlagenbau, or German Engineering<br />
Federation). Almost three quarters of these companies are<br />
expecting in the coming 24 months an upward trend in their<br />
business in Germany. Yet the technology can only utilize<br />
its full potential when it is integrated successfully in highly<br />
automated industrial process chains.<br />
How this works is demonstrated in the Additive Manufacturing<br />
Area. Here companies will be presenting pioneering<br />
concepts from the whole bandwidth of the additive process<br />
chain, whether direct and indirect 3D printing technologies,<br />
engineering materials, or rapid product development (RPD).<br />
Connectivity of production processes at a glance<br />
In digital production machines must be able to communicate<br />
with each other, irrespectively of their make, age, or controller.<br />
The Future of Connectivity Area therefore focuses on<br />
these processes. Here visitors will encounter new applications,<br />
automation processes, smart production, Industry 4.0,<br />
machine learning, predictive maintenance, IIoT (Industrial<br />
Internet of Things), and many other aspects. And the editorial<br />
series Future of Connectivity will also be reporting on<br />
these subjects in the run-up to EMO Hannover.<br />
Humans and robots work hand in hand<br />
More and more companies are investing heavily in automation<br />
to maintain their productivity and competitive strength,<br />
to augment their resilience and versatility, and to keep pace<br />
with growing demands. For instance the number of new<br />
industrial robots installed in 2021 exceeded the 500,000 mark<br />
for the first time – a new record. Specifically cobots, or collaborative<br />
robots, are in high demand. They already now make<br />
up 7.5 % of all installed industrial robots, and this is an upward<br />
trend.<br />
The Open Space Cobot Solutions Area is therefore fully<br />
dedicated to the interactions between humans and industrial<br />
robots and their actual and potential applications. Manufacturers<br />
will be presenting to an international trade public<br />
their automation solutions based on cobots and their innovative<br />
use: grippers, image processing, measuring systems,<br />
software, industrial electronics, feed systems, and much more<br />
can be experienced up closely.<br />
Sustainability to underlie tomorrow’s production<br />
The declared goal of the 2015 Paris agreement is to limit the<br />
rise in mean global temperature to a maximum of 2° C. At the<br />
latest since then it has become clear: the subject of sustainability<br />
is seen as a challenge of global import affecting society<br />
as a whole. Among other intentions, the European Union<br />
has resolved as a result to render its economy and society carbon-neutral<br />
by 2050. The manufacturing industry too is feeling<br />
the considerable effects, and it sees itself faced with equally<br />
imposing challenges – and opportunities.<br />
At EMO Hannover <strong>2023</strong>, the Future of Sustainability in<br />
Production Area provides the ideal environment for experiencing<br />
the latest solutions for tomorrow’s production. Here<br />
visitors can learn about the current trends in energy efficiency,<br />
the integration of renewable energies, circular economy,<br />
and lifecycle concepts – a fair highlight, not only with<br />
an eye to climate protection and reduced production costs in<br />
times of persistently scarce energy and raw materials.<br />
further information: www.emo-hannover.de<br />
no. 2, May <strong>2023</strong><br />
25
news & facts<br />
fairs<br />
parts2clean <strong>2023</strong><br />
Industrial parts cleaning redefined<br />
As a result of structural changes in industry, plus<br />
several new megatrends and the energy transition<br />
itself, the tasks and requirements in industrial parts<br />
and surface cleaning are also in a perpetual state of<br />
change.<br />
The 20 th parts2clean takes this development into<br />
account with an expanded range of solutions and a<br />
new highlight topic: “High purity”. This anniversary<br />
edition of the leading international trade fair for industrial<br />
parts and surface cleaning will take place<br />
September 26 to 28, <strong>2023</strong>, at the Stuttgart exhibition<br />
grounds.<br />
As the leading international networking hub for industrial<br />
parts and surface cleaning, parts2clean reflects the requirements<br />
of a number of user industries and offers a globally<br />
unique portfolio of solutions. This will become even clearer<br />
at this year’s anniversary event, thanks to an expanded<br />
range of offerings and the event’s new claim titled “Cleaning<br />
redefined”.<br />
In the words of Hendrik Engelking, global director at<br />
Deutsche Messe: “In addition to the familiar core areas of<br />
industrial parts cleaning, we are thus also covering new and<br />
ever-changing tasks that arise – for example from the mobility<br />
and energy turnaround, the trends of automation, digi -<br />
tization and AI, sustainability, and, in some industries,<br />
stricter regulatory requirements. For example cleaning solutions<br />
for electronics manufacturing, e-mobility, sensor technology,<br />
optical industry, medical and pharmaceutical technology<br />
will play a greater role,” he adds. And the energy efficiency<br />
of cleaning systems and processes is another area to<br />
be covered by the upcoming parts2clean.<br />
High purity –<br />
more than just cleaning<br />
For the first time in parts2clean’s twenty-year history, this<br />
year’s edition will feature a highlight topic, “High purity”.<br />
“The focus here will be on tasks that need to be solved,<br />
among other things, for complex mechanical components for<br />
the semiconductor supplier industry, in the precision optics<br />
and optoelectronics industry, thin-film technology, medical<br />
technology, as well as vacuum-technology components for<br />
the UHV, XHV and UCV sectors,” reports Engelking.<br />
The extremely stringent specifications for ultra-fine particulate,<br />
film-chemical, organic and inorganic purity required<br />
in these areas can only be met if the entire process<br />
chain is taken into consideration. Of course, the cleaning<br />
system also plays an important role here, but factors such<br />
as the cleanliness of the pre-processes, production materials<br />
and media, handling influences and ambient conditions,<br />
for example an adapted cleanroom, are just as decisive for<br />
stable, achievable results. It is also important to avoid recontamination<br />
and cross-contamination.<br />
Future-proof solutions for<br />
current and future requirements<br />
“With its expanded range of solutions, as well as the highlight<br />
topic of high purity, parts2clean continues to gain in<br />
attractiveness as the world’s most important tradeshow for<br />
industrial parts and surface cleaning,” reports Engelking.<br />
And this is also the case in industrial sectors that may not<br />
have felt addressed in the past. This is because the cross-sector<br />
and cross-material offerings also enable companies to find<br />
out about cleaning applications and solutions in sectors of<br />
industry in which they have not previously been active. In<br />
addition users from all manufacturing sectors as well as from<br />
remanufacturing and recycling will find future-proof solutions<br />
to meet current and new require ments in a stable and<br />
efficient manner.<br />
Knowledge transfer included –<br />
bilingual expert forum<br />
The bilingual expert forum will also make a valuable contribution.<br />
The simultaneously translated (German English)<br />
presentations by renowned speakers from science, research<br />
and industry will address current tasks and developments<br />
from a number of different business sectors. “parts2clean<br />
thus offers national and international visitors one of the most<br />
sought-after sources of knowledge for learning about trends,<br />
innovations, benchmark applications and reports from the<br />
field,” says Hendrik Engelking. The knowledge meeting<br />
point, which is organized jointly with the Fraunhofer-Business<br />
Area “Cleaning” and the German Industrial Parts Cleaning<br />
Association (FiT), is integrated into the flagship trade fair,<br />
and attendance is free of charge for visitors and exhibitors.<br />
further information: www.messe.de<br />
26 no. 2, May <strong>2023</strong>
fairs<br />
news & facts<br />
The Champions League<br />
of the industry in one place<br />
Moulding Expo will highlight the importance and efficiency<br />
of the tool, pattern and mould making industry.<br />
Tools and moulds are required in every industry in order to<br />
be able to manufacture high-quality products in large unit<br />
numbers. It is therefore becoming increasingly more important<br />
to organise the production process in an even more<br />
efficient and cost-effective way, and also take account of<br />
integrated solutions.<br />
A key role in this respect is played by reliable and innovative<br />
tool construction partners with modern and highly<br />
automated production as well as corresponding experience<br />
and know-how. Leading tool, pattern and mould making<br />
com panies will demonstrate their expertise and offer solutions<br />
for different branches of industry at Moulding Expo<br />
June 13 – 16, <strong>2023</strong>.<br />
“We are looking forward to welcoming around 400 exhibitors<br />
at Moulding Expo <strong>2023</strong>. These exhibitors will include<br />
the champions league of the tool, pattern and mould making<br />
industry along with relevant technology suppliers. Product<br />
developers, tool buyers, plastics processors and operators<br />
of an internal or external tool, pattern and mould making<br />
facility should plan a visit to Moulding Expo,” said Florian<br />
Niethammer, head of Trade Fairs & Events at Messe Stuttgart.<br />
Under one roof at Moulding Expo the exhibitors will present<br />
customised solutions for different industries – for example<br />
the automobile industry, the aerospace industry, the electrical<br />
engineering industry, medical technology, mechanical<br />
engineering and the photovoltaic industry.<br />
The international trade fair is divided into several exhibition<br />
areas. The focal point of Moulding Expo is the tool, pattern<br />
and mould making industry which is very user-oriented<br />
with its injection moulding tools, die-cast moulds and forming<br />
tools, as well as gauge construction and jig and fixtures<br />
manufacturing. The trade fair will also feature systems and<br />
services relating to plastics technology and metal working:<br />
from suppliers of machine tools, clamping devices, machining<br />
tools and measuring systems, and suppliers of materials,<br />
standard components and hot runner systems through to<br />
software companies.<br />
further information: www.messe-stuttgart.de<br />
Fourth annual Open House & Technology Days<br />
Ready to take efficiency in manufacturing to the next<br />
level? ZOLLER’s fourth annual Open House & Technology<br />
Days event will take place May 9-11, <strong>2023</strong>, at<br />
ZOLLER’s state-of-the-art North American headquarters<br />
in Ann Arbor, Michigan. More than 300 guests<br />
attended last year’s event and organizers expect this<br />
year’s program to attract even more attention.<br />
Over the span of three days participants can network and<br />
learn from the best in the industry, including ZOLLER<br />
experts, loyal customers and other industry leaders. They<br />
will discover the latest developments in tool presetting, tool<br />
inspection and tool management technology and how the<br />
entire process chain of ZOLLER Solutions can increase productivity<br />
and efficiency in a connected and scalable way.<br />
More than a dozen speakers are expected to present during<br />
the three-day event. ZOLLER president Alexander Zoller will<br />
provide the keynote address on his vision for success in smart<br />
manufacturing at shops of all sizes. Each day will also include<br />
tech talks, breakout sessions and live demos, including interactive<br />
demonstrations of the new ZOLLER tool balancing<br />
and heat shrinking solutions, toolholders and the “roboSet 2”<br />
24/7 tool inspection automation solution.<br />
The Open House & Technology Days event will also feature<br />
demos of the entire suite of ZOLLER solutions. Participants<br />
can learn how to implement the industry’s best tools to maximize<br />
efficiency and control over their tooling and production<br />
processes.<br />
further information: www.zoller.info<br />
no. 2, May <strong>2023</strong><br />
27
news & facts<br />
LACH DIAMANT – 100 Years<br />
Tradition. Passion. Innovation<br />
part 5:<br />
The dawn of a new age of cutting technology –<br />
from a natural diamond cutting company<br />
to the pioneer of polycrystalline diamond<br />
and CBN tooling<br />
“When I held my first diamond in my hand in 1908, I would not<br />
have imagined that one day diamonds would not only be used in the<br />
automobile industry but also for the machining of wood and plastics”.<br />
Jakob Lach, the company founder, said this on camera in 1980.<br />
It would become the preface for the first presentation of a new technique<br />
for machining wood and plastics – using diamonds as cutting<br />
material – the Dia Tool. This video, with audio translated into<br />
multiple languages, has lost none of its relevance for the choice of<br />
appropriate tools within the furniture, flooring and composite industries;<br />
the video can be viewed at: https://bit.ly/LACHDIAMANT<br />
Company founder Jakob Lach, 1894-1984<br />
(photo taken in 1980)<br />
The year is 1973. 50 years ago. Energy crisis,<br />
marked by the first major oil crisis. Fuel prices<br />
were skyrocketing. The first automobile-free<br />
days. Highways were left to pedestrians and<br />
bikers. VW built its first water-cooled front<br />
engine and celebrated its premiere with the<br />
“Passat.”<br />
LACH DIAMANT, the diamond tool manu -<br />
facturer from Hanau (previously known as<br />
the city of fine jewellery) is in the midst of a<br />
eupho ric growth spurt. On top of a wave of<br />
success thanks to the newly developed CBN<br />
grinding wheels with Borazon® (CBN), an<br />
abrasive for grinding HSS and high-alloy<br />
hardened steel.<br />
During this exuberant euphoria, the “advertisers”<br />
at LACH DIAMANT were bold<br />
enough to publish a persiflage brochure,<br />
“warning” customers of Borazon®, on one of<br />
the tradeshows in Hanover 1970/71. The slogan<br />
“Do you want to play cards too?” was not<br />
always well-received.<br />
This development came at a price, the available<br />
space at the property at Bruchköbeler<br />
Landstr. 39 was bursting at all seams. This<br />
Polycrystalline diamonds (PCD),<br />
manufacturing process and division into<br />
solderable inserts – size as of 1973 – for the<br />
manufacturing of cutting tools (GE graphics);<br />
today PCD blanks are available up to 0 70 mm<br />
28 no. 2, May <strong>2023</strong>
news & facts<br />
Borazon® advertising “warning” all tool grinding shops of extended tooltimes,<br />
and that their employees will have time to play cards due to shortened grinding times<br />
with Borazon® – “Do you also want to play cards?”<br />
was true for both manufacturing and administration. All capacities<br />
for setting up new automoulders or expanding the<br />
turning shop were exhausted. The development of the fallow<br />
property no. 41 promised relief. A double- storey factory<br />
building for the production of resin and metal bond diamond<br />
and Borazon® (CBN) grinding wheels, including a turning<br />
shop was constructed on the site. A four-storey office building<br />
was built as well. The entire complex was finished 1972.<br />
For the first time, during the expansion of both diversification<br />
of business and product portfolio, things had calmed<br />
down… if there had not been an increasing persistent rumour,<br />
end of 1972/beginning 1973, about a new synthetic cutting<br />
material, developed by US-manufacturer General Electric. The<br />
available, scattered information did not allow any conclusion<br />
about which type of cutting material came in question. Fact<br />
was that the company “Carboloy”, a GE-affiliate, kept compact<br />
boron nitrite inserts (turning inserts) in stock since approximately<br />
1970, so I guessed it to be a Borazon® cutting material<br />
(at this point, Carboloy probably had no interest in a<br />
cutting material superior to carbide, and rather sold carbide).<br />
Another cutting material, for example based on “diamond”,<br />
would not be under consideration according to my thoughts<br />
at that time. How could it be? Compared to “diamond”, a<br />
cutting material containing Borazon®/CBN would have the<br />
best sales prospects and the best chance in the hardened steel<br />
machining industry.<br />
Rumours about a new cutting material<br />
With natural diamonds at our disposal, and with the<br />
LACH DIAMANT cutting shop, we were best suited for our<br />
production of natural diamond turning steel and for turning<br />
of copper commutators for customers like Bosch, Siemens,<br />
AEG etc.<br />
We received note of this new cutting material end of<br />
March/beginning of April 1973, just in time to introduce it at<br />
the coming Hanover spring tradeshow in April.<br />
In order to invite potential major customers to this tradeshow,<br />
my research led me to a ferrous material named “Ferro<br />
Titanit” by DEW, the German Ferrous Material Factory in<br />
no. 2, May <strong>2023</strong><br />
29
news & facts<br />
Krefeld. My acquisition efforts and the announcement<br />
of a coming new “CBN compact”<br />
material was immediately met with spontaneous<br />
approval from the DEW board of directors.<br />
A few days later, two members of the<br />
board sat in my father’s parlour and listened<br />
to my presentation; my explanations were<br />
mainly justified by my knowledge of the machining<br />
of high-alloy steel with Borazon®/<br />
CBN grinding wheels.<br />
You, my dear reader, will forgive me this<br />
(premature) gaffe, the gentlemen from DEW<br />
however did not and later were disappointed.<br />
The surprise came only a few days later. It was<br />
not a compact Borazon®/CBN cutting material,<br />
as I had speculated, but it was “diamond.” To<br />
be more exact: polycrystalline synthetic diamond,<br />
by now commonly known under its acronym<br />
“PCD”.<br />
The first PCD inserts came as 90 ° and 60 °<br />
segments, cut out of a blank with a diameter<br />
of “only” 3.2 mm. The visible PCD diamond<br />
layer of approx. 0.3 to 0.4 mm was joined to a<br />
carbide metal holder, with the effect that the<br />
cutting edge could be further processed by<br />
brazing.<br />
Initial grinding tests<br />
It was Friday, exactly three work days before<br />
the opening day of the tradeshow April 26 th ,<br />
1973. Proudly I presented the first PCD to<br />
Kurt Wagner, head of our natural diamond<br />
cutting shop, and an exceptionally gifted diamond<br />
cutter who had top-notch experience<br />
from his employment as a diamond specialist<br />
at a Swiss manufacturer of turning tools for<br />
jewellery and watches. After a thorough exam -<br />
ination and grinding tests on a diamond dust<br />
coated, cast grinding wheel (obviously meant<br />
for natural diamonds), he explained to me:<br />
“Boss, we usually do everything you ask for,<br />
but this stuff is so beastly and isn’t naturally<br />
grown, there is nothing we can do!” Great, I<br />
thought, probably that was it. What now? We<br />
did not have the luxury of many more grinding<br />
options at that time. But then I remembered<br />
our Simon steel grinding machine<br />
(L15). This machine had been purchased during<br />
our cooperation with the company Simon,<br />
Neu-Isenburg, a distributor of resin and metal<br />
bond diamond wheels. I remember to this<br />
day saying to myself: “Then let’s try it on the<br />
Simon machine with a cup wheel!”<br />
And sure enough, the first grinding test<br />
with the resin bond diamond grinding wheel<br />
was already promising. However it still was an<br />
effort of several hours in order to achieve the<br />
desired geometry of the cutting edge.<br />
Grinding of a polycrystalline turning steel on a Simon steel grinding machine<br />
This stuff lasts so long…<br />
Right on time for the tradeshow start at 9 a.m., our driver Mr. Barmus delivered<br />
the first PCD tool to our booth at the fair. It would henceforth bear<br />
the registered name “dreborid®”. Wednesday and Thursday the driver came<br />
again with yet another turning tool, until we explained to him: “This stuff<br />
lasts so long” that he would not have to bring any more tools.<br />
By the way, technically speaking “the stuff lasts so long” is equivalent to<br />
“tool life.” We did not make any statements in this regard at the Hanover<br />
tradeshow – how could we – after just a few hours experience during the<br />
turning of an aluminium part. The part contained bore holes in different<br />
sizes in order to simulate interrupted cuts.<br />
Presentation of the first dreborid turning steel with simulated, interrupted cut<br />
during the machining of aluminum at the Hanover spring tradeshow in 1973<br />
30 no. 2, May <strong>2023</strong>
news & facts<br />
Cautiously one or the other LACH DIAMANT<br />
technician answered respective questions,<br />
estimating a tool life 10-20 times longer than<br />
compared with a carbide blade, and naturally<br />
even greater compared to an HSS turning tool.<br />
Today we know that compared to all abrasive<br />
materials, such as SiC containing aluminium,<br />
bronze, fiber-glass (GRP) and carbon fiber<br />
(CFRP) containing materials, ceramic components,<br />
all wood materials/composites, the<br />
durability is more than two to three hundred<br />
times as long. I deliberately mention “copper”<br />
last. For the second time in the company’s<br />
history, “copper” opened the door to further<br />
economic growth.<br />
Once again the copper commutators which<br />
are necessary for the perfect functioning of<br />
electric motors played an important role. In<br />
the 1960’s, 20-30 cutters of natural diamonds<br />
helped to replace carbide turning tools with<br />
diamond tipped tools. With such natural<br />
diamonds it was possible to turn 30 commutators,<br />
and in one case up to 120,000 pieces<br />
perfectly. Companies like Bosch, Siemens<br />
and AEG profited from tools made by LACH<br />
DIAMANT, and especially from our regrinding<br />
service.<br />
Engineer Karl Krügel’s (†) demonstration of application was received with<br />
astonishment and, in most cases, with enthusiasm by tradeshow visitors<br />
Expanding the customer base<br />
However both we and our customers had to<br />
accept that tool life was still rather inconsistent.<br />
When the cutters were asked they just<br />
shrugged their shoulders and answered: “It’s<br />
natural diamond, naturally grown, unique<br />
and different, just like humans.” We were fully<br />
aware of this fact when we brainstormed<br />
potential applications and potential customers<br />
for this compact polycrystalline diamond<br />
composite.<br />
PCD gave us the chance to expand our customer<br />
base, including other manufacturers<br />
of copper commutators. Our cutting shop for<br />
natural diamonds was at full capacity.<br />
When doing my research one company<br />
caught my interest, one that was apparently<br />
also involved in the production of commutators.<br />
Our first conversation however was not<br />
encouraging. They manufactured “raw commutators”,<br />
delivered them to our current customers,<br />
not turned but ground.<br />
To Kautt & Bux this seemed an interesting<br />
thought. Turning instead of grinding? This<br />
would save a lot of time. We agreed to meet<br />
at the tradeshow. Unlike with DEW (machining<br />
FerroTitanit) it was a success. Still at the<br />
tradeshow, we received the first order for ten<br />
dreborid® PCD turning tools.<br />
First information on dreborid® PCD cutting inserts,<br />
published for the Hanover tradeshow in April 1973<br />
no. 2, May <strong>2023</strong><br />
31
news & facts<br />
A win-win situation for LACH DIAMANT<br />
and all of our customers. Our first major customer,<br />
Kautt & Bux, could boast to be the<br />
first company in the world to use polycrystalline<br />
diamonds in serial production. The entire<br />
manufacturing process was converted to<br />
turning the copper commutators.<br />
A walk with consequences<br />
Now let’s take a look back at the production<br />
situation at the company premises at Bruchköbeler<br />
Landstrasse. The production of resin<br />
and metal bond diamond Borazon® CBN<br />
grind ing wheels as well as the production of<br />
single diamonds and polished profile and<br />
copy diamonds were booming. Space for new<br />
installations of now necessary tool grinding<br />
machines for the production and grinding<br />
of PCD tools was limited, not to mention<br />
the installation of a separate production section.<br />
That was the situation then, although the<br />
company had just completed a large building<br />
extension project.<br />
Turning of a copper commutator with one of the first<br />
newly-manufactured dreborid® PCD tools<br />
Out of the blue Jakob Lach, already 79<br />
years of age, made a suggestion. On one of<br />
his walks, not too far from us, approximately<br />
2 km away, he had discovered a promising<br />
property with a large building in the back – a<br />
former diamond sawmill. So we rented the<br />
property. With the result that our just previously<br />
installed wheel production, including<br />
all of the pressing machines, had to be moved<br />
and make room for our laboratory and turning<br />
shop. Manufacturing, construction and<br />
development of polycrystalline tools for<br />
copper, aluminium and composite machining<br />
was now done in our original building<br />
at Bruchköbeler Landstrasse, and we then<br />
were able to develop the knowhow that today<br />
distinguishes the LACH DIAMANT company<br />
as a technological pioneer.<br />
How things proceeded with “100 years<br />
of LACH DIAMANT”, will be revealed in<br />
the 6 th installment of this article series. It<br />
will contain exciting and so-far unpublished<br />
details regarding the first-ever presentation<br />
of new tool blades.<br />
Yours, Horst Lach<br />
further information: www.lach-diamant.de<br />
Are you enjoying this history of<br />
LACH DIAMANT?<br />
You can download part 1 - 4<br />
(from 1922 through 1972) for free at:<br />
https://bit.ly/anniversary-series<br />
The fast-growing dreborid® PCD programme for machining aluminium,<br />
copper, graphite and composite materials<br />
32 no. 2, May <strong>2023</strong>
processes<br />
Sustainable process chains for the manufacture<br />
of resilient and smart tools<br />
Whether drilling, turning or milling: in machining –<br />
as well as in primary forming and re-forming, die casting<br />
and many other applications – tools are of pivotal<br />
importance for industrial production. Their performance<br />
significantly influences both the quality and the<br />
cost of the manufactured product and, consequently,<br />
the economic and ecological sustainability of the production<br />
process. One objective of the work at the<br />
Fraunhofer Institute for Surface Engineering and<br />
Thin Films IST in Braunschweig is the development of<br />
resilient and smart tools under the requirements of<br />
sustainability.<br />
The researchers thereby take the entire process chain into<br />
ac count – from tool design and material char ac ter i zation,<br />
through pre-treatment, cleaning, and customized surface<br />
treat ments and coatings, and on to testing and application.<br />
The key to the manufacture of resilient high-tech tools<br />
which retain their value-adding and economic operability<br />
under even the highest stresses is an optimized tool construction.<br />
This encompasses both the selection of the material<br />
and the design, thereby taking into account geometry and<br />
topography as well as the use of heat treatments and suitable<br />
coatings. At the Fraunhofer IST optimizations in the manufacturing<br />
process are therefore investigated throughout the<br />
entire process chain. The process begins with an analysis or<br />
characterization of the materials to be machined and an optimum<br />
design of the tool, which also includes the selection of<br />
a suitable coating.<br />
The actual production process for the tools begins with<br />
the manufacture of the basic body. Following pre-treatment,<br />
Tools coated with CVD diamond<br />
e.g. etching, sandblasting and cleaning, the focus is directed<br />
on the optimal design of the surface. Depending on the tool<br />
and its intended use this can, for example, be hardening by<br />
means of plasma diffusion treatment or a customized coating.<br />
In addition to access to a wide range of technologies<br />
and industrial equipment, the experts at the Fraunhofer IST<br />
can draw on many years of experience and user knowledge,<br />
enabling, for example, friction and wear properties to be<br />
specifically adjusted and tool life to be optimized. In order to<br />
exploit all efficiency potentials in terms of both energy and<br />
resource consumption, they combine the tribological functional<br />
coatings with thin-film sensor technology where necessary.<br />
Very thin sensor layers, directly in the main stress<br />
zones of the tools, enable the recording of relevant process<br />
data such as pressure, temperature or wear. These so-called<br />
smart tools therefore fulfil the prerequisites for the digitalization<br />
of processes and process chains and, furthermore, offer a<br />
diverse range of approaches for the optimization of production<br />
in terms of quality, safety, productivity and flexibility.<br />
The concluding step in the process chain is the testing and<br />
quality assurance of the tools. For the sustainability assessment<br />
of the various measures, development-related life-cycle<br />
analyses (LCA, LCC) are performed at the institute.<br />
The use of resilient and smart tools in conjunction with a<br />
digital process chain offers major potential for safe, efficient,<br />
flexible and sustainable production and can therefore provide<br />
a contribution towards increasing Germany’s competitiveness<br />
and securing its position as a production location.<br />
On the Fraunhofer joint stand in the “Production” section<br />
at Hannover Messe, the Fraunhofer IST demonstrated<br />
the potential of coating and surface technology for the manufacture<br />
of sustainable tools. Exhibits included cobalt-free<br />
carbides for machining, service-life-optimized tools with<br />
CVD diamond coating and smart and resilient tools for die<br />
casting and re-forming.<br />
Diecasting cores during plasma nitriding<br />
further information: www.ist.fraunhofer.de<br />
no. 2, May <strong>2023</strong><br />
33
processes<br />
Additive-subtractive manufacturing of<br />
clamping systems for the machining of<br />
CFRP components<br />
written by<br />
Thomas Götz and Andreas Gebhardt,<br />
Fraunhofer Institute for Manufacturing Engineering and Automation IPA<br />
The machining of components made of carbon<br />
fiber reinforced plastics (CFRP) requires the use of<br />
clamping technology adapted to the task. The following<br />
article deals with the production of such clamping<br />
systems by means of a hybrid production of extrusionbased<br />
3D printing and a machining finishing process.<br />
CFRP are becoming increasingly widespread due to their<br />
excellent lightweight construction properties and flexible<br />
shaping within manufacturing. A significant advantage of<br />
fiber reinforced components lies both in the possibility of<br />
designing the construction and material architecture in line<br />
with the load and in manufacturing the component nearnet-shape.<br />
However, this results in further necessary processing<br />
steps for the final completion in the area of the component<br />
edge as well as for functionalisation, for example by<br />
inserting holes, pockets or recesses. Machining processes<br />
are typically used for this, but the processing is associated<br />
[1, 2]<br />
with certain challenges.<br />
Due to the largely open and large-surface design of cfrp<br />
components, they are usually unstable and prone to vibration<br />
despite their high rigidity, which impairs both the service life<br />
of the cutting tools used and the machining quality [3] .<br />
Clamping systems for CFRP components<br />
To avoid negative effects during finishing, different clamping<br />
systems are used (figure 1), which are principally designed<br />
either on the basis of the geometry of the workpiece [4] and/<br />
or the maximum cutting force components resulting from<br />
the machining process [5] . The state of the art includes, for<br />
example, jigs that represent a negative shape of the CFRP<br />
component. This means that the component rests on the<br />
entire surface and can usually be clamped with low vibration<br />
by means of vacuum [3] . Since these jigs are milled from<br />
a plastic or metal block, their production is associated with<br />
a high time and equipment-specific effort, high costs and<br />
low resource efficiency. Another unfavourable effect is that<br />
functionalities such as vacuum fields or channels for suction<br />
through the jigs can only be produced with great effort [6] ,<br />
as complex, multi-sided drilling and milling operations are<br />
required. Moreover, the massive and therefore heavy jigs<br />
can usually only be transported with industrial trucks and<br />
require adequately designed warehousing and storage logistics,<br />
which generates further costs [7] .<br />
jig (A. Gebhardt)<br />
vacuum clamping system<br />
(J. Schmalz GmbH)<br />
mould clamping system<br />
(MATRIX GmbH)<br />
figure 1<br />
llustration of the described clamping systems<br />
34 no. 2, May <strong>2023</strong>
processes<br />
Against the background of the problems of massive threedimensional<br />
jigs, developments of modular clamping systems<br />
for the finishing of CFRP components were advanced<br />
and marketed. On the one hand, the use of modular clamping<br />
systems consisting of adjustable vacuum clamps and precisely<br />
positioned counterholder pins is suitable for secure and<br />
low- distortion fixing of workpieces with free-form surfaces.<br />
On the other hand, vacuum clamping systems are being used<br />
that have rotatable and height-adjustable suction cups, are being<br />
used, whereby the individual clamping surfaces themselves<br />
are only flat and thus have limitations in adapting to<br />
the shape of the component.<br />
Due to the easy adaptability of the flexible vacuum clamping<br />
systems to different component contours, they are particul<br />
arly suitable for small batch sizes. However, given the<br />
more flexible supports and lower vibration damping, they<br />
lead to reduced tool life and machining quality. In addition,<br />
the manual adjustment effort is high, resulting in higher setup<br />
[3, 7]<br />
times.<br />
granular plastics<br />
extrusion screw<br />
platform<br />
extrusion<br />
unit<br />
nozzle<br />
3D object<br />
In the area of form-flexible clamping systems, there are<br />
further solutions based on the pincushion principle, which<br />
allows the fixing of different workpieces by means of grouped<br />
plungers and adapts to the shape of the component. After<br />
hugging the workpiece surface, the plungers are locked for<br />
machining, decoupled at the end of the process and can thus<br />
move back to their original position [8] .<br />
In view of the deficiencies of existing clamping systems,<br />
it may be advisable to first manufacture near-net-shape jigs<br />
using an additive manufacturing process and then reworking<br />
the functional surfaces by machining for high dimensional<br />
accuracy and surface quality. In this way hybrid production<br />
can significantly shorten the time-consuming and<br />
labor intensive process chain of component manufacturing.<br />
Additive manufacturing of<br />
large-volume components<br />
Additive manufacturing involves processes in which components<br />
are built up layer by layer [9] . Depending on the ad ditive<br />
manufacturing process, the physical principles of producing<br />
of individual layers differ, whereas the basic process<br />
figure 3<br />
Fused granular fabrication [12]<br />
chain is process-independent and consists of several successive<br />
steps (figure 2).<br />
The process begins with a three-dimensional CAD data set<br />
that represents the component to be manufactured. In the<br />
following step, the so-called slicing process, the CAD data<br />
set is divided into layers and contour paths with the help of<br />
special slicer software. Subsequently, traverse commands,<br />
consisting of G-code with additional information (print head<br />
temperature, bed temperature, traverse speeds), are transmitted<br />
to the printer, which then executes these machining<br />
instructions. The physical model thus grows layer by layer<br />
until the component is finished, removed from the machine<br />
for machining post-processing. [10]<br />
For the additive manufacturing of large-volume jigs, the<br />
process of direct granulate extrusion (figure 3) is suitable. In<br />
this process, thermoplastic standard granulate is conveyed<br />
CAD model of<br />
the component<br />
converting the 3D model<br />
into printing instructions<br />
virtual level<br />
additive manufacturing of the<br />
component layer by layer<br />
physical<br />
component<br />
physical level<br />
figure 2<br />
Process chain of additive manufacturing of components [10]<br />
no. 2, May <strong>2023</strong><br />
35
processes<br />
through a screw extruder, melted and compacted<br />
to a homo geneous mass. The melted<br />
mass is then pressed through a nozzle, whereby<br />
the discharged material diameter is determined<br />
by the nozzle’s diameter and the extrusion<br />
rate. Layer by layer, the plastic mass is extruded<br />
according to the specified contour data<br />
on the building platform. [11, 12] Here, the possible<br />
component size is limited solely by the<br />
travel distance of the extruder, with a trend<br />
towards large format additive manufacturing<br />
with construction volumes ranging from 1 m 3<br />
up to 25 m 3 [13] .<br />
(1) static-mechanical<br />
analysis<br />
(3) smoothing of<br />
the mesh structure<br />
(2) topology-optimised<br />
analysis<br />
The granulate-based extrusion process is<br />
characterized by low costs, the high build-up<br />
rates (several kg per hour) and the possibility<br />
of producing large functional and structural<br />
components. Drawbacks, however, are the low<br />
resolution and surface quality as well as the<br />
anisotropy of the components and the associated<br />
lower strength in the build-up direction<br />
as compared to the selective laser sintering<br />
[14, 15]<br />
process.<br />
Prototypical production of<br />
a highly integrative jig<br />
Starting from the CAD model of a massive<br />
jig for a complex 3D CFRP component, a topology-optimized<br />
model was derived using<br />
the CAD software AUTODESK FUSION 360<br />
(figure 4). After defining the areas to be retained,<br />
the geo metrically modifiable design<br />
space and the mass target (50 %), the vacuum<br />
clamping and feed forces acting on the jig were<br />
defined. While the vacuum clamping force<br />
is applied to the top of the jig as a surface load,<br />
(4) CAD feedback<br />
figure 4<br />
Steps in topology optimization<br />
the feed force acts tangentially to the machining edge of the workpiece. Subsequently,<br />
the stress distributions under the defined loads were calculated as<br />
part of the static-mechanical analysis, a mass-optimized model was designed<br />
and fed back into a surface model. For the application case of machining, it<br />
should be taken into account that the feed force has a time-shifted dynamic<br />
course along the machining edge. Therefore, it can be assumed that the high<br />
criticality of the load path applies to the entire edge area and is not limited to<br />
the area shown above.<br />
Based on the findings of the topology investigation, a mass-optimized jig<br />
was derived, taking into account manufacturing aspects of additive manufacturing.<br />
Subsequently, the jig was manufactured using a hybrid production<br />
sealing cord<br />
milled surface<br />
vacuum<br />
channels<br />
figure 5<br />
Additive-subtractively manufactured jig<br />
tensioning<br />
template<br />
connection<br />
plate<br />
36 no. 2, May <strong>2023</strong>
processes<br />
process of extrusion-based 3D printing and post-machining<br />
(figure 5). The jig has a grid-like structure in the areas that<br />
have proven to be uncritical with regard to the load path in<br />
the context of topology optimization which simultaneously<br />
serve as recesses for applying the negative pressure. The<br />
design also had to take into account process-relevant functionalities<br />
such as a circumferential groove for receiving the<br />
sealing cord or an offset as a material addition for the final<br />
machining of the contact surface of the subsequent component.<br />
By avoiding support structures and material accumulation,<br />
a significant reduction in material use and thus also production<br />
times could be achieved which leads to a further increase<br />
in the efficiency of the additive manufacturing process<br />
as com pared to the production of a conventional solid jig.<br />
In addition, the thermally induced distortion could be<br />
greatly reduced by optimizing the printing path parameters.<br />
Summary and outlook<br />
The potential of additive-subtractively manufactured jigs<br />
for the machining of CFRP components is already evident.<br />
The advantages lie in the manufacturability of batch-sizeindependent,<br />
individual end products, which allow the economic<br />
integration of functionalities such as vacuum fields,<br />
milling and suction channels.<br />
In addition the targeted insertion of hollow structures allows<br />
significant weight savings, which can lead to easier handling<br />
and greater material efficiency.<br />
Further investigations into the general process suitability<br />
of the jig for real CFRP components, especially with regard<br />
to the special requirements regarding component sizes in the<br />
aerospace industry, as well as the circular economy are the<br />
subject of current and future research work.<br />
Literature<br />
[1]<br />
Spur, G.; Heisel, U.; Klocke, F.; Eckart, U. (2014)<br />
Handbuch Spanen<br />
München: Carl Hanser Verlag<br />
[2]<br />
Rüger, O.; Fröhlich, F. (2011)<br />
Endkonturnahe Fertigung von CFK-Bauteilen<br />
Lightweight Design 4<br />
[3]<br />
Moser, S.; Gauggel, C. (2017)<br />
Die 10 wichtigsten Fakten zur CFK-Zerspanung<br />
Produktion 14, Internet:<br />
hwpcom.guehring.de/wp-content/uploads/2018/dokumente/News/Produktion_0417.pdf<br />
[4]<br />
Lin, Z.; Yabg, C. (1995)<br />
An Expert System for Fixturing Design for Face Milling<br />
Using Modular Fixture<br />
International Journal of Advanced Manufacturing Technology<br />
10, 6, pp. 379 - 388<br />
[5]<br />
Mahmud, A.; Mayer, J.; Baron, L. (2015)<br />
Determining the minimum clamping force by cutting force<br />
simulation in aerospace fuselage pocket machining<br />
International Journal of Advanced Manufacturing Technology<br />
80, 9–12, pp. 1751 - 1758<br />
[6]<br />
Gebhardt, A.; Schneider, M. (2018)<br />
Späne- und Stauberfassung bei der CFK-Zerspanung<br />
wt WerkstattsTechnik online 108, 6, p. 473–478,<br />
Internet: www.werkstattstechnik.de,<br />
Düsseldorf: Springer-VDI-Verlag<br />
[7]<br />
Götz, T. (2018)<br />
Entwicklung funktionsintegrierter 3D-gedruckter Spannmittel<br />
für dünnwandige CFK-Bauteile<br />
8. IfW-Tagung: Bearbeitung von Verbundwerkstoffen,<br />
29.11.2018, Stuttgart<br />
[8]<br />
Königsreuther, P. (2011)<br />
Formflexibles Spannsystem passt sich<br />
jeder Kontur leicht an<br />
MaschinenMarkt 9, p. 1 - 5,<br />
Internet: www.maschinenmarkt.vogel.de/formflexiblesspannsystem-passtsich-jeder-kontur-leicht-an-a-333110<br />
[9]<br />
Gibson, I.; Rosen, D.; Stucker, B. (2015)<br />
Additive manufacturing technologies: 3D printing, rapid<br />
prototyping and direct digital manufacturing<br />
New York, Heidelberg, Dordrecht, London: Springer<br />
[10]<br />
Gebhardt, A. (2014)<br />
3D-Drucken<br />
Grundlagen und Anwendungen des Additive Manufacturing<br />
(AM). München: Carl Hanser Verlag<br />
[11]<br />
Weißgraeber, P.; Heieck, F.; Ackermann, C. (2020)<br />
Advances in Automotive Production Technology –<br />
Theory and Application<br />
Stuttgart Conference on Automotive Production<br />
(SCAP2020)<br />
[12]<br />
N. N.<br />
Fused Granular Fabrication, FGF<br />
Manufacturing Guide Sweden AB, Stockholm, o. J.,<br />
Internet: https://www.manufacturingguide.com/en/<br />
fused-granular-fabrication-fgf<br />
[13]<br />
Moreno Nieto, D.; Casal López, V.; Molina, S. I. (2016/18)<br />
Large-format polymeric pellet-based additive manufacturing<br />
for the naval industry<br />
Additive Manufacturing, volume 23, p. 79 - 85, 2018,<br />
doi: 10.1016/j.addma.2018.07.012<br />
[14]<br />
Breuninger, J.; Becker, R.; Wolf, A.; Rommel, S.; Verl, A.<br />
(2013)<br />
Generative Fertigung mit Kunststoffen: Konzeption und<br />
Konstruktion für Selektives Lasersintern<br />
Berlin, Heidelberg: Springer<br />
[15]<br />
Tofail, S. A. M. et al. (2018)<br />
Additive manufacturing: scientific and technological challenges,<br />
market uptake and opportunities<br />
Materials Today, volume 21, n° 1, p. 22 - 37, 2018,<br />
doi: 10.1016/j.mattod.2017.07.001<br />
further information: www.ipa.fraunhofer.de<br />
no. 2, May <strong>2023</strong><br />
37
processes<br />
Design, manufacture and inspection<br />
in a smart loop<br />
At JIMTOF 2022 Gleason presented the latest gear<br />
design, manufacturing and inspection systems in challenging<br />
times of transformation. Exhibits and live streams<br />
with KISSsoft’s design software release 2022, new gear<br />
chamfer cutting technologies, hard finishing of gears<br />
by Super Finish Honing, Combi Honing and Polish<br />
Grinding, Hobbing and Power Skiving on one flexible<br />
platform, revolutionary gear metrology systems with<br />
laser scanning, sub-micron inspection and in-pro cess<br />
gear inspection with integrated gear noise ana ly sis.<br />
KISSsoft® design and transmission software presented its latest<br />
2022 release with a wealth of new features and functionalities<br />
including Smart Loop feedback to production machinery<br />
for fast and efficient design adjustments in the prototyping<br />
phase, integrating design into manufacturing and inspection<br />
processes.<br />
Gleason’s 300GMSL Gear Metrology System features laser<br />
scanning for gear inspection at the speed of light, providing<br />
the data for unprecedented real-time analytics to speed up<br />
the development of complex gears, maximize efficiency, and<br />
minimize sound emissions in EV and other gearboxes.<br />
The new 300GMS nano Gear Metrology System provides<br />
for gear inspection capability at submicron level, integrating<br />
highly sophisticated tools to analyze waviness for profile,<br />
lead and pitch, and to determine gear noise characteristics of<br />
e-drive gears.<br />
Exhibits were complemented by manufacturing and inspection<br />
demonstrations via live streams from global Gleason<br />
operations worldwide presenting new developments in Hard<br />
Power Skiving, medium size bevel gear cutting, gear honing<br />
by Super Finishing for excellent surface finishes, threaded<br />
wheel grinding for gears with mirror-like surfaces and 100 %<br />
in-process gear inspection.<br />
On November 10, 2022, Gleason had invited customers<br />
to the traditional Dr. Stadtfeld Day at Tokyo Big Sight.<br />
Dr. Stadtfeld presented the latest developments for the future<br />
of bevel gear manufacturing, including flexible cutting with<br />
Superi-Ac® Ecoblade RT, psychoacoustic noise reduction with<br />
MicroformTM, Coniflex® Plus for strong and quiet e-drive<br />
differentials, bevel gear e-drive concepts and a brand-new<br />
process for fast cutting of differential gears.<br />
further information: www.gleason.com<br />
38 no. 2, May <strong>2023</strong>
processes<br />
Greater efficiency thanks to<br />
digital assistance systems<br />
in machine tools<br />
In the private sphere, digital assistance and communication<br />
systems have become indispensable.<br />
In a professional environment, even outside the office,<br />
supporting systems are increasingly gaining<br />
equal status. As a machine tool manufacturer, the<br />
UNITED GRINDING Group offers digital products<br />
that not only make work easier for its customers but<br />
also save time and money.<br />
What makes working on machines in an industrial facility<br />
easier? “That I can get help quickly and easily when the machine<br />
stops” could be the answer from a machine operator. A<br />
maintenance employee may say “That I have an overview of<br />
all upcoming maintenance tasks and thus no longer miss any<br />
important schedules”. The answer from the production manager<br />
might be “That I can also see whether all the machines<br />
in my production are running when I’m on the road.”<br />
Different user groups have varying demands on modern<br />
production. As one of the world’s leading machine tool<br />
manu facturers, the UNITED GRINDING Group offers<br />
digital assistance systems that make work easier for various<br />
user groups.<br />
Remote service<br />
Remote service offers uncomplicated and fast assistance, for<br />
example, in the event of machine downtime. By triggering a<br />
service request, customers can request quick and uncomplicated<br />
help by pressing a button. This service request can be<br />
submitted by the customer via a smartphone and the corresponding<br />
digital solutions app or via the customer cockpit.<br />
With a machine equipped with the modern C.O.R.E. technology,<br />
this is now even possible directly on the machine. In<br />
addition, a video conference can be conducted via the integrated<br />
camera in the C.O.R.E. panel. This again significantly<br />
increases the benefit provided by service support. Also the<br />
whiteboard function makes it easy to share drawings and<br />
notes on pictures or documents. This way the customer care<br />
team can assist remotely, saving time and money.<br />
Service monitor<br />
The service monitor relieves those responsible for maintenance<br />
by displaying clearly all the important maintenance<br />
tasks based on the current machine’s operating hours. The<br />
service cockpit can be even used to centrally manage, moni tor<br />
and document maintenance due dates for several connected<br />
machines. Only necessary maintenance work is displayed.<br />
Unnecessary work is thus avoided. But the necessary work<br />
that ensures the smooth operation of a machine is not forgotten.<br />
Thanks to this optimal maintenance and care, the availability<br />
and working life of the machine is increased, which in<br />
turn has a positive effect on productivity.<br />
Remote service digital solutions<br />
Production monitor<br />
Production managers can monitor the production output of<br />
the machinery at any time by using the production monitor.<br />
Production benchmarks, such as operating and non-productive<br />
times, production quantities and downtimes, are displayed<br />
in real-time. The latest version also supports the global<br />
communication standard umati UA4MT (Universal Machine<br />
Technology Interface for Machine Tools). Not only machines<br />
from the UNITED GRINDING Group but also machines<br />
from other manufacturers can be easily integrated<br />
into the production monitor – from anywhere and at any<br />
time – thanks to the digital solution app. This overview makes<br />
it possible to discover optimization potential in the production<br />
and operation of the machines.<br />
Growing importance of digitization<br />
UNITED GRINDING Digital Solutions products were<br />
presented to an interested audience at the MECSPE <strong>2023</strong><br />
trade show in Bologna. As a result of the corona pandemic<br />
the overall importance of digital assistance systems has increased<br />
noticeably. Remote solutions were the only way to<br />
stay in contact with customers and provide assistance during<br />
lockdown periods. During this phase UNITED GRINDING<br />
had more than 2,500 remote deployments worldwide. The<br />
trend towards flexible working models and working from<br />
home or on the road has also driven the demand for appbased<br />
solutions. Digital assistance systems are already an indispensable<br />
part of everyday production, and demand will<br />
be rising. The UNITED GRINDING Group is continuously<br />
expanding the functionalities of its current products and<br />
constantly adding to its range of digital solutions.<br />
further information: www.grinding.ch<br />
no. 2, May <strong>2023</strong><br />
39
machining center<br />
Grinding requires smart automation<br />
Faster, more accurate and more cost-efficient machining<br />
is only one of the advantages of automating<br />
grinding processes. Factors such as a higher safety for<br />
the operators and their health also play a large role.<br />
STUDER is therefore one of the technology leaders<br />
in this field.<br />
“There are still a lot of prejudices about automation in grinding,”<br />
says Daniel Schafroth, systems division manager at<br />
STUDER. There are frequently concerns that people or jobs<br />
could become redundant. “However, for us at STUDER, the<br />
opposite holds true: automation should enable the human operators<br />
to do their work more easily, efficiently, and safely,”<br />
he says. Additionally the special requirement of grinding necessitates<br />
that automation is used very wisely and selectively<br />
not every solution used in the industry is suitable for this. But<br />
what are the important factors?<br />
“For grinding it is particularly important that processes<br />
are performed repeatedly in the same way, with high precision<br />
and reliability, for example clamping workpieces and<br />
aligning them correctly with micrometer accuracy,” explains<br />
Schafroth. Automatic solutions for multi-machine operation<br />
are also relevant, as these can greatly relieve the workload<br />
of the operators, who then only have to fill magazines<br />
and no longer need to laboriously load each machine. However,<br />
grinding fundamentally requires the operators to have<br />
a high level of competence, and automation should not be<br />
something that hinders them,” says Schafroth: “Automation<br />
only makes sense where the operator doesn’t have to have a<br />
decisive influence on the process.”<br />
Daniel Schafroth,<br />
systems division manager, Fritz Studer AG<br />
Small companies profit from easyLoad<br />
If correctly used, automation can be a real game changer for<br />
grinding companies – regardless of whether it is a small business<br />
or a large company with several systems. “Where grinding<br />
machines are concerned, automation pays off for all sizes<br />
of companies,” emphasizes Schafroth. This may mean that a<br />
small workshop with only a few employees can fill the grinding<br />
machine in the morning and let it work autonomously<br />
for extended periods while the employees take care of other<br />
things, such as writing quotations. For example the easyLoad<br />
loading system for external and universal cylindrical grinding<br />
machines (S31, S33, S22 and S41), which offers excellent<br />
value for money, including integration in the machine control,<br />
is explicitly also aimed at small companies.<br />
easyLoad is suitable for use as a gantry loading system for<br />
shaft parts with a workpiece length of up to 300 mm (11.8“), 0<br />
up to 30 mm (1.18“), and interfering contour 0 of max. 50 mm<br />
(1.97”). The adjustable synchronized conveyor allows autonomous<br />
processing of max. 50 workpieces. The standard gripper<br />
Adjustable synchronized chain with<br />
prism supports for up to 50 workpieces<br />
Loading and unloading situation<br />
with STUDER roboLoad<br />
40 no. 2, May <strong>2023</strong>
machining center<br />
STUDER S31<br />
with new uniLoad loading system<br />
STUDER S131 Radius<br />
internal cylindrical grinding machine<br />
with roboLoad loading system<br />
is designed for individual parts, the V-gripper for two parts,<br />
and the heavy-duty gripper for workpieces that weigh more<br />
than 5 kg (11 lbs.), and the changeover time is only around six<br />
seconds. This enables the machine to run autonomously for<br />
half an hour or longer with ease.<br />
ecoLoad and uniLoad increase production<br />
STUDER has also developed optimal automation solutions for<br />
larger-volume series production. “Small companies mainly<br />
benefit from the universal and flexible systems, whereas<br />
speed and precision are the important factors in the production<br />
of large quantities,” explains Schafroth. Here good automation<br />
concepts can produce a large number of high-quality<br />
workpieces and make the most of every second. The ecoLoad<br />
for the STUDER S22 production platform is an automatic<br />
loading system for series production using high-speed grinding,<br />
production-oriented cylindrical grinding, as well as form<br />
and thread grinding.<br />
ecoLoad can load workpieces with 0 of up to 50 mm (1.97”)<br />
and a length of 250 mm (9.85”). This is either done using a<br />
carousel magazine or an insertion prism, which can also be<br />
used as the interface for standalone tool magazines. The programming<br />
is already integrated into the grinding machine<br />
control. This ensures short retooling times.<br />
The uniLoad automatic loading system also makes it possible<br />
for operators of the STUDER S31 and S33 external cylindrical<br />
grinding machines to significantly increase productivity<br />
without any loss of quality. The system docks to the<br />
machine from the left. With a prismatic conveyor and all<br />
racks at full capacity, it can perform automatic processing<br />
for around an hour. It is suitable for workpieces with a<br />
length of up to 350 mm (13.8”) and 0 100 mm (3.94”) and thus<br />
covers a large range of the parts normally produced on these<br />
machines.<br />
Automation when space is tight:<br />
smartLoad and roboLoad<br />
Solutions for applications with limited space are another important<br />
trend in the automation of grinding. “In modern production<br />
halls, it is of particular importance to make efficient<br />
use of the space,” says Schafroth. This is another topic where<br />
STUDER is a trailblazer, for example with the smartLoad for<br />
the S11, a production cylindrical grinding machine for small<br />
workpieces which has a footprint of only 1.8 m 2 (19.4 ft 2 ).<br />
The smartLoad unit is also compact and can feed in workpieces<br />
from outside the machine, using either a conveyor or<br />
a swivel ing unit, as well as clamp them and place them back<br />
after the machining. Thanks to the wide variety of configuration<br />
options numerous applications are possible, for both<br />
small and large-volume series.<br />
Advantages at a glance:<br />
➤ automation in grinding protects the health of the<br />
operators and makes their workplaces safer and<br />
more comfortable<br />
➤ in small grinding companies with few employees,<br />
automation gives the staff more time for other tasks<br />
➤ in large-series production and mass production,<br />
grinding machines with automation can process large<br />
quantities very quickly and with consistent quality<br />
➤ smart, network-capable software and digital assistance<br />
systems form part of automation, because they make<br />
the work easier and faster for the operators and<br />
increase the quality<br />
STUDER has developed optimal automation solutions for a<br />
variety of applications: easyLoad (S31, S33, S22 and S41),<br />
ecoLoad (S22), smartLoad (S11), uniLoad (S31 and S33), as<br />
well as roboLoad (S121 Radius, S131 Radius, S141 Radius)<br />
no. 2, May <strong>2023</strong><br />
41
machining center<br />
In the past, radius internal cylindrical<br />
grinding machines, which are used in the<br />
manufacturing of drawing dies, for example,<br />
have been particularly difficult to automate,<br />
due to the limited space available. One reason<br />
for this is the restricted enclosure geometry<br />
resulting from the high workhead. STUDER<br />
has now developed an optimal solution for<br />
this as well: roboLoad.<br />
This external loader for the S121, S131 and<br />
S141 is designed as a gripper arm with quickchange<br />
jaws and has a lot of space for workpieces<br />
on six trays (each 1080 x 320 mm (42,5<br />
“ x 12.6”)). At 1.50 m (59”), the system is only<br />
half the width of the machine itself.<br />
“With the robot arm outside the machine,<br />
we gain a lot more freedom, thanks to the<br />
rotation axis, and the roboLoad can get in<br />
for loading and unloading without having a<br />
direct path available,” says Schafroth. Until<br />
now, automation solutions for grinding were<br />
largely based on linear technology such as<br />
beams and slides. However, at the moment the<br />
roboLoad is not primarily intended for large<br />
series production, but more for automated<br />
production during night shifts or extended<br />
breaks. But Schafroth is sure that the trend<br />
toward using robotic arms in grinding will<br />
persist. “Neither our customers nor we want<br />
to relinquish this new freedom.”<br />
Automation is digital as well<br />
This freedom includes easy and intuitive operation,<br />
a special USP of roboLoad and the<br />
other STUDER concepts. “The grinding machine<br />
operators do not need any programming<br />
skills to perform the setup; it can be<br />
done easily and quickly within a matter of<br />
minutes,” says Schafroth. For him, automation<br />
in grinding means more than just physical<br />
machine support. It is equally important<br />
to have digital assistance, such as that offered<br />
by the STUDER grinding software and in particular<br />
C.O.R.E., the revolutionary new crossbrand<br />
hardware and software architecture of<br />
the UNITED GRINDING Group.<br />
On the large C.O.R.E. touch display with<br />
intuitive icons, the operators can quickly<br />
find what they need and important information<br />
regarding the machining process is displayed.<br />
RFID access chips can be used to let<br />
the machine only display the options and information<br />
for which the individual users are<br />
qualified. “This prevents unqualified employees<br />
from making changes that could cause an<br />
error or a crash,” explains Schafroth. With<br />
applications of UNITED GRINDING Digital<br />
Solutions, efficient remote monitoring of<br />
STUDER S22<br />
with ecoLoad loading system on the right<br />
Grid rack of the STUDER roboLoad<br />
the machines is possible even today, and in the future machines will monitor<br />
themselves for optimal functioning and proactively provide information on<br />
required maintenance measures.<br />
The possibilities for automation in grinding are therefore very diverse and<br />
offer large advantages on different levels. However, as Schafroth emphasizes,<br />
the focus must always remain on people. “Something that is frequently overlooked<br />
regarding this topic is that automation also protects the safety and<br />
health of the workers.” Robots can not only help with lifting heavy loads and<br />
performing repetitive, boring tasks but also handle a wide range of different<br />
materials without problems. This makes the workplace a lot safer and more<br />
comfortable. Schafroth says that he is happy that the prejudices regarding<br />
the topic are decreasing and that automation solutions are becoming more<br />
and more frequent in grinding, and adds: “Because the best machine technology<br />
in the world is useless if it is not accepted by the people.”<br />
further information: www.studer.com<br />
42 no. 2, May <strong>2023</strong>
machining center<br />
New femtosecond laser solutions<br />
On February 21, <strong>2023</strong>, at an Open House event<br />
held in its Laser Center of Technologies in Geneva<br />
(Switzerland) with more than 70 international VIP<br />
guests, GF Machining Solutions presented its new<br />
LASER S 1000 U fs and LASER S 1200 U fs machines<br />
in an exclusive preview. The two solutions are equipped<br />
with new ultrashort pulse laser sources and are now<br />
available for sale.<br />
The<br />
launch of<br />
the two new laser<br />
machines is expected to<br />
increase the adoption of laser<br />
in industries such as automotive,<br />
for example for lighting molds<br />
Ultrashort pulse laser sources are well known for their<br />
excellent machining quality, achieving finest details and<br />
better surface roughness compared to nanosecond laser<br />
sources. The first machine equipped with an ultrashort pulse<br />
laser was the AgieCharmilles LASER P 400 U, which introduced<br />
this powerful tool for texturing and engraving into the<br />
market.<br />
Thanks to latest developments, GF Machining Solutions’<br />
AgieCharmilles LASER S 1000 U fs and AgieCharmilles<br />
LASER S 1200 U fs are now also equipped with a fiber femtosecond<br />
laser. This will ensure a laser machining process<br />
capable of creating finest details with enhanced quality while<br />
maintaining a high performance. It will also allow the processing<br />
of a wider range of materials that only femtosecond<br />
laser sources are able to machine efficiently, like ceramics,<br />
glass, sapphire etc..<br />
The launch of these two new machines is expected to<br />
increase the adoption of laser as a technical manufacturing<br />
solution in industries such as automotive (for lighting, interior<br />
and exterior design), packaging and ICT. Nanolaser<br />
capabilities often could not satisfy requirements like the<br />
machining of complex, small geometries, a no-heat affected<br />
zone and the necessary surface roughness needed for applications<br />
in these industries.<br />
Users will maintain the upmost flexibility thanks to the<br />
possibility to combine a nanosecond and a femtosecond laser<br />
source in the same machine, switching seamlessly between<br />
the two sources in the same job. Depending on the appli -<br />
cation and the desired results, it is possible to use the<br />
strengths of each laser source for the best combination of<br />
quality and productivity. The new femtosecond options<br />
work in perfect union with the latest software developments<br />
launched by GF Machining Solutions in 2022: flexiblast TM<br />
and 3DCurves TM .<br />
Thanks to the new<br />
machines, the crewith<br />
enhanced quality,<br />
shown on this lotus flower,<br />
capabilities of the<br />
ation of finest details<br />
like the ones<br />
will be possible<br />
“We believe that the new femtolaser capabilities that we are<br />
integrating into our large laser machines will not only meet<br />
the needs of our existing customers active in laser texturing<br />
and engraving, but also open up space for new applications<br />
in micromachining, attracting new customers in further segments<br />
like semiconductors or aerospace”, says Stefan Dahl,<br />
COO of GF Machining Solutions.<br />
The LASER S 1000 U fs and the LASER S 1200 U fs<br />
do not only offer extreme machining speed, but can also<br />
achieve higher quality and better surface roughness<br />
thanks to the new laser sources<br />
further information: www.gfms.com<br />
no. 2, May <strong>2023</strong><br />
43
machining center<br />
The European debut of the<br />
Supfina Fact<br />
As one of the global leaders in surface finishing<br />
technologies, the Supfina team presented an innovation<br />
to interested parties at Global Industrie <strong>2023</strong>. The<br />
new Supfina Fact superfinishing attachment was presented<br />
to the European professionals for the first time.<br />
Fast action changing tool<br />
With its small, compact design the Supfina Fact tape finishing<br />
attachment is ideal for use in revolver lathes. Additionally<br />
the surface qualities that can be achieved are much higher<br />
than those achieved with standard turning. This means that<br />
even the highest surface requirements will be fulfilled.<br />
Functionally perfect surfaces<br />
Whether it’s low-volume attachments or complete machining<br />
solutions with automation, Supfina works together with the<br />
clients to review their existing production structure and meet<br />
any requirements in the following areas:<br />
➤ superfinishing<br />
➤ flat finishing<br />
➤ fine grinding<br />
➤ double-disk grinding<br />
➤ attachments<br />
➤ automation and robotics<br />
Solutions from a single source<br />
As a solution provider Supfina advises prospects and customers<br />
on their individual challenges, validates parameters and<br />
uses its own studies to develop the appropriate machining<br />
solution. In addition, a later integration into existing production<br />
structures, sustainable automation and IT infrastructure<br />
is taken into account.<br />
Superfinishing attachment fact<br />
➤ small compact design for mounting on the<br />
revolver of lathes<br />
➤ drive for the oscillation and the tape feed via<br />
a central drive from the revolver of the lathe<br />
➤ flushing through the revolver to the pressure roller<br />
➤ no additional media connections are required<br />
➤ adaptation to different turret systems possible<br />
➤ oscillation shutdown for twist-free machining<br />
through special gear is possible<br />
In particular the automation of loading and unloading<br />
through robot-assisted process automation is currently<br />
a strong demand f.e. due to the lack of skilled workers. “Our<br />
customers are increasingly demanding sophisticated systems<br />
for their production processes,” explains Dominik<br />
Maier, business unit manager, “whether complex automation<br />
or upstream and downstream processing, we deliver the<br />
solution.”<br />
A comprehensive, modern range of services is available,<br />
from maintenance to production and process support to<br />
individual training.<br />
further information: www.supfina.com<br />
44 no. 2, May <strong>2023</strong>
Precise sharpening for wood and co.<br />
machining center<br />
In the wood industry, circular saws, drills or<br />
milling cutters are indispensable for the efficient processing<br />
of wood and composite materials. Visitors to<br />
LIGNA <strong>2023</strong> woodworking trade fair can find out how<br />
these tools can be machined with the highest precision<br />
at the international sharpening specialist Vollmer.<br />
The company will be providing comprehensive insights into<br />
its range of machines with which customers can machine<br />
their circular saws and rotary tools – regardless of whether<br />
these are made of carbide, PCD (polycrystalline diamond) or<br />
other cutting materials. Automation enables unmanned 24/7<br />
shifts and digital V@dison solutions optimise tool machining<br />
and increase transparency through the rapid availability of<br />
machine data and information.<br />
Grinding and eroding machines for<br />
drills and milling cutters<br />
In addition to circular saws, drills and milling cutters are<br />
also used for cutting wood and composite materials. Vollmer<br />
has developed its VGrind grinding machines to produce<br />
rotary tools such as these from carbide. They have two vertically<br />
configured grinding spindles and allow efficient multi -<br />
level machining. This time the VGrind argon will be at LIGNA<br />
trade fair.<br />
The VHybrid 260 grinding and eroding machine also<br />
features multi-level machining, with the lower spindle<br />
capable of both grinding and eroding. Thanks to a new<br />
V@dison solution, the VHybrid 260 achieves a surface finish<br />
of 0.05 μm/Ra (micron/center roughness value) when eroding<br />
PCD tools. Also on show at LIGNA is the QXD 250 disc<br />
erosion machine, which is suitable for sharpening PCD tools<br />
with diameters of up to 320 millimeters and weights of up<br />
to 25 kilograms.<br />
Vollmer provides information about its services<br />
Vollmer’s presence at LIGNA fair will be completed with<br />
services for maintenance, servicing, training, financing and<br />
digitalisation. Among them are offers of the V@dison digital<br />
initiative, which include, for example, the “Performance<br />
Package for VHybrid 260” V@ boost solution.<br />
further information: www.vollmer-group.com<br />
no. 2, May <strong>2023</strong><br />
45
components<br />
Filtration solutions for coatings and<br />
finish applications<br />
State-of-the-art filtration solutions seal the deal between<br />
improved performance and sustainability<br />
in industrial applications<br />
The Filtration Division of power management<br />
company, Eaton exhibited how its filtration solutions<br />
designed for coatings and finishes applications help<br />
improve performance and sustainability at European<br />
Coatings trade show in Nuremberg, Germany.<br />
The exhibition program included diverse and effective filtration<br />
solutions for removing solids and oil from paint, coatings,<br />
varnishes, adhesives, sealants, additives and printing<br />
inks. These solutions allow for more efficient production<br />
lines, less maintenance downtime and reduced waste.<br />
The focus was on Eaton’s comprehensive bag filtration solutions.<br />
Eaton’s TOPLINE single bag filter housing is designed<br />
for a large variety of applications and can either be used as<br />
a single housing or connected in a parallel arrangement.<br />
It features a side inlet, flow-through top for easy and quick<br />
filter bag change-outs and provides optimum sealing of the<br />
filter bag to help prevent product loss. To meet the special<br />
filtration requirements of paints, coatings and varnishes<br />
in the automotive industry, it can be equipped with highstrength<br />
filter bags from the LOFCLEAR 100 (automotive)<br />
range. When used with Eaton’s HAYFLOW filter elements or<br />
MAX-LOAD pleated filter bags, the number of change-outs<br />
can be reduced, resulting in improved operating efficiencies,<br />
reduced operation costs, and reduced waste volume.<br />
Eaton’s extended-life, pleated MAX-LOAD<br />
needle-felt filter bags with outer cage, SENTINEL seal ring<br />
and thermo-bonded end caps for maximum<br />
dirt-holding capacity even under harsh conditions<br />
Eaton’s PED-compliant Simplex 72X pipeline basket<br />
strainers in ductile iron and stainless steel are designed<br />
to protect process equipment in various chemical,<br />
petrochemical and water applications<br />
Another highlight was Eaton’s automatic filter family for<br />
processes where a complete shutdown is not an option. A part<br />
of this automatic filter family showcase is the range of DCF<br />
mechanically cleaning filters that is ideal for highly viscous,<br />
abrasive, or sticky liquids – including paint. It operates at a<br />
consistently low differential pressure and deliver simple, reliable<br />
operation in which a low initial investment is a key driving<br />
factor.<br />
The exhibition program was rounded off with the Simplex<br />
72X cast pipeline strainer range. It is available in six standard<br />
sizes and conforms to the Pressure Equipment Directive<br />
(PED) with sealing and surface finishing characteristics, superior<br />
to previous models. The strainer range is CE-marked<br />
to PED and is compliant with the EN13445 and AD 2000<br />
pressure vessel codes. The Simplex 72X strainers provide<br />
full bypass-free filtration which protects process equipment.<br />
Typical applications for the strainers include chemical, petrochemical<br />
and water pipelines where temporary shutdown for<br />
cleaning or changeout is possible.<br />
further information: www.eaton.com<br />
46 no. 2, May <strong>2023</strong>
The world’s first e-chain made entirely of recycled material<br />
Conserving resources and<br />
extending the product life cycle<br />
components<br />
More sustainability with consistent quality: the new cradle-chain<br />
made of recycled material conserves resources and drives<br />
the circular economy forward<br />
Cradle-to-cradle: this is the principle of the circular<br />
economy which is abased on nature. The aim: to return<br />
consumer goods to the biological or technical cycle in<br />
order to conserve valuable resources and raw materials.<br />
The motion plastics specialist igus is also pursuing<br />
this goal and has now developed the world’s first energy<br />
chain made from recycled material on the basis of its<br />
own “chainge” e-chain recycling program.<br />
From extreme weather and natural hazards to marine pollution,<br />
the climate crisis is getting worse and more and more<br />
people are becoming aware of it. “Even the purchasing decisions<br />
of our customers are increasingly being shaped by ecological<br />
considerations. That is why we have put a lot of effort<br />
into product development in order to be able to produce more<br />
resource-efficiently – without sacrificing product quality,”<br />
explains Jörg Ottersbach, head of the igus e-chains business<br />
unit. The result: the E2.1.CG cradle-chain – a complete<br />
range of e-chains made from the new igumid CG material.<br />
Numerous tests in their test laboratory show that the new<br />
e-chain has almost the same technical properties and load<br />
limits as an energy chain made from the standard igumid G<br />
material. Another advantage is that the cradle-chain is available<br />
at the same price as e-chains made from the standard<br />
material. The new range is available from stock in five series<br />
and 28 chain types.<br />
From discarded e-chain to recycled material<br />
The cradle-chain uses, among other things, recycled material<br />
from the “chainge” recycling program. As part of this<br />
program igus has been collecting used energy chains from<br />
customers since 2019 so that they will not end up in industrial<br />
waste. This service is offered for both igus e-chains and<br />
chains from other manufacturers. So far more than 32 tons<br />
of material have been collected from 13 countries.<br />
Scrap material is sorted by type, cleaned and processed to<br />
new quality. This is possible with the help of a chemical analysis<br />
and formulation tuning, a process in which material is<br />
optimized for the desired properties and therefore enables<br />
constant product quality. The post-consumer material igumid<br />
CG is then used to make the recycled cradle-chain – without<br />
any loss of quality in terms of wear behaviour, stability or<br />
bending fatigue.<br />
Sustainable raw material cycle –<br />
with 28 % less CO 2<br />
With the new e-chain product range made of recycled material,<br />
igus is making a further contribution to conserving<br />
resources and advancing the circular economy. According<br />
to the Environment Product Declaration, this sustainable<br />
raw material cycle also reduces CO 2 emissions by 28 %. Jörg<br />
Ottersbach says, “The focus should not only be on first use<br />
of products, but also the reuse of raw materials. We see a lot<br />
of ‘cradle-to-cradle’ potential and strive to reprocess as many<br />
raw materials and discarded products as possible so that<br />
precious resources are not waste, but used wisely for as long<br />
as possible.”<br />
further information: www.igus.eu<br />
no. 2, May <strong>2023</strong><br />
47
components<br />
The ES951 spindle and MyHSD,<br />
a high performance combination<br />
We have entered the heart of the production plants<br />
of Mecal Machinery srl and Oddicini srl, two Italian<br />
companies based respectively in Frascarolo (PV) and<br />
Gravellona Toce (VB), which have been choosing and<br />
relying on HSD technological solutions for years.<br />
In particular Mecal Machinery is a company specialized<br />
in the production of machines and systems for processing<br />
aluminium, PVC and light alloys. Oddicini, using Mecal<br />
machinery, is a company that creates operable partitions,<br />
customizable with any finish and raised floors designed for<br />
any use.<br />
Meeting Rosella Meschini, co-owner and sales director of<br />
Mecal Machinery, and Susanna Cane, CEO of Oddicini, we<br />
had the opportunity to investigate and explore the experience<br />
of two consolidated customers who have chosen to use within<br />
their production processes HSD components; and more<br />
specifically, to discover the innumerable advantages deriving<br />
from the new ES951 wi-fi electrospindle connected to the<br />
IoT platform, MyHSD. The ES951 range of electrospindles,<br />
developed to equip 3-axis machining centers and robotic<br />
applications, offers the possibility of choosing from a wide<br />
range of motorizations and is characterized by an integrated<br />
IoT system.<br />
First of all, Mecal Machinery chose to incorporate the new<br />
wi-fi electrospindle into its machining centers, immediately<br />
understanding the great added value that this would generate<br />
for its machinery, helping to improve performance and quality<br />
standards. “The new ES951 spindle and the My HSD platform<br />
are a high-performance combination because we are<br />
going to combine the performance of the spindle with<br />
the possibility of detecting all the data that it can transmit<br />
remotely, making it possible to monitor everything that is<br />
happening on the spindle in realtime” – Davide Rubin, UTE/<br />
service manager Mecal Machinery srl.<br />
The MyHSD platform was developed with the aim of “providing<br />
our customers with a wide range of services and benefits,<br />
such as reduction of maintenance costs, real-time data<br />
analysis to convert them into useful information, improvement<br />
of customer knowledge on the use of the electrospindle<br />
and the provision of useful information for research and development,<br />
to improve processes and optimize maintenance<br />
through timely notifications and guided troubleshooting<br />
procedures” – Fabrizio Pierini, general manager of HSD.<br />
These advantages are inevitably crucial not only for<br />
Mecal, but also and above all for those who use Mecal machinery<br />
equipped with the HSD wi-fi spindle, such as Oddicini<br />
for example. In fact, what prompted the Piemontese company<br />
to choose this combination within its machining center<br />
was “the possibility of preventing breakdowns, because<br />
in the company, unfortunately, machine downtime due to<br />
a sudden breakdown represents considerable damage to the<br />
production and to the consequent costs for management” –<br />
Susanna Cane, CEO of Oddicini.<br />
48 no. 2, May <strong>2023</strong>
components<br />
The monitoring offered by MyHSD does not just avoid failures,<br />
but it anticipates them. The predictive maintenance<br />
strategies exploit the innovative e-core sensor technology,<br />
which combined with distributed algorithms between platform<br />
and device, provide the user with timely notifications<br />
on the replacements to be made, thus maximizing the machine<br />
up-time. The HUB function, patented by HSD, allows<br />
to transfer machine tool information to the MyHSD platform<br />
such as: process data, statistical values and the status<br />
of the machining center. This feature allows to exploit the<br />
potential of MyHSD not only on the spindle but also on the<br />
machine. Furthermore, the MyHSD premium package embraces<br />
a holistic approach to predictive maintenance, providing<br />
the operator with a complete overview of the entire<br />
system, and also ensuring a greater capacity for prediction<br />
and analysis, thus favouring a drastic reduction of potential<br />
financial losses.<br />
Using the computer or smartphone application, the user is<br />
able to “see the vibration levels of the spindle, how many rotations<br />
it is working at and if we are carrying out particularly<br />
complex or heavy machining” – Gabriele Morandi, maintenance<br />
manager of Oddicini srl. A combination between the<br />
ES951 wi-fi electrospindle and the MyHSD platform, capable<br />
of increasing the performance of the machining center<br />
on which the spindle is installed and significantly improving<br />
LIGNA <strong>2023</strong><br />
HSD products dedicated to wood processing include the<br />
Wi-Fi ES951 range of electrospindles designed to equip<br />
3-axis machining centers and robotic applications,<br />
offering to choose from a wide range of motorisation<br />
options. Customers can configure their electrospindle with<br />
3-phase asynchronous motors and power ratings from<br />
6.5 kW – 25 kW, and select compressed air, electric fan<br />
or liquid cooling systems. The entire ES951 range allows<br />
interaction with the machine via a selection of IoLink,<br />
Ethercat or Canopen fieldbuses, offering a version with<br />
an HSD-produced MEMS accelerometer and a thermal<br />
probe to monitor the temperature of the front bearings<br />
among other options.<br />
The ES951 electrospindle range also features an integrated<br />
IoT system for connecting to the My HSD IoT platform for<br />
a high-performance combination. In this arrangement<br />
the spindle can capture all the data, allowing real time<br />
monitoring on the spindle.<br />
the use of the machinery by the end user, having the ability<br />
to promptly implement any corrective actions to prevent and<br />
avoid breakdowns and consequent machine downtime.<br />
Digitization and connectivity are nowadays essential<br />
elements to consider in the offer of a product, capable of simplifying<br />
the processes of the customers and consequently<br />
improving their competitiveness on the market.<br />
HSD has been a forerunner of the industrial digitalization<br />
with its e-core products on the market for over 10 years<br />
and today, with the ever-increasing development of the IoT<br />
world, it is able to offer its customers the innovative MyHSD<br />
predictive maintenance platform. A platform whose application<br />
will also be extended from <strong>2023</strong> to other models of electrospindles,<br />
such as those dedicated to metalworking, with<br />
the ultimate aim of meeting and increasingly satisfying the<br />
different needs of the customers<br />
further information: www.hsd.it<br />
no. 2, May <strong>2023</strong><br />
49
components<br />
Coolant filtration as a value-adding factor<br />
Optimally filtering and cleaning cooling lubricants<br />
Vomat demonstrated high-performance ultrafine filtration technology during GrindTec<br />
In tool grinding all influencing parameters in the<br />
overall cutting chain must be perfectly coordinated.<br />
Cleaned coolants and lubricants are an important<br />
piece in the mosaic. At GrindTec <strong>2023</strong> the filtration<br />
specialist Vomat from Treuen showed solutions on<br />
how tool manufacturers can realize high quality and<br />
economic efficiency with optimally filtered coolants.<br />
In tool grinding coolants are on the one hand a cost factor<br />
and on the other hand an important quality-determining<br />
parameter, and the longer the cleaned coolant can remain in<br />
the system the less coolant it requires, storage and recycling<br />
costs are reduced, and also the grinding wheels do not have<br />
to be changed or dressed as often.<br />
Steffen Strobel, technical sales manager at Vomat says,<br />
“Vomat FA filtration systems are ideal for filtration of ultra-fine<br />
particles from grinding oils. Important features include<br />
full-flow filtration with 100 % separation of dirty and<br />
clean oil, on-demand filtration and backwashing of the highperformance<br />
precoat filters, and high-precision temperature<br />
accuracy.”<br />
On the standard platform of the FA machine series, individually<br />
tailored concepts – from small-scale systems to<br />
industrial central filtration solutions – can be configured<br />
thanks to a wide range of optional add-on modules.<br />
further information: www.oelheld.com<br />
50 no. 2, May <strong>2023</strong>
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CERATIZIT Deutschland GmbH ......................................front cover<br />
Kapp GmbH & Co. KG ..................................................page 9<br />
Lach Diamant Jakob Lach GmbH & Co. KG ............................. back cover<br />
rose plastic AG .........................................................page 15<br />
ZECHA Hartmetall-Werkzeugfabrikation GmbH ..........................page 13<br />
no. 2, May <strong>2023</strong><br />
51
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