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 />


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 />


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 />


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 />


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 />



IS KING<br />


Push the king off his throne?<br />

Really hard. But our Circle Up<br />

packaging also has a lot to offer:<br />

plenty of recycled material.<br />

To keep it that way, there’s only<br />

one thing you need to do:<br />

Recycle!<br />

www.rose-plastic.de/en/<br />


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 />


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 />


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 />


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 />


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 />


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 />


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 />


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 />


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 />


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 />


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 />


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 />


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 />


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 />


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 />


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 />


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 />


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 />


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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advertising index<br />

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 />


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