hpt 2023 #3

Portfolio for automated electrode production / Using high performance, high-end tools in mould making / Lightweight damper system for use in lightweight structures / What to expect at EMO

Portfolio for automated electrode production / Using high performance, high-end tools in mould making /
Lightweight damper system for use in lightweight structures / What to expect at EMO


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ISSN 2628-5444<br />

high precision tooling<br />

Machine Tools, PCD, PVD, CVD, CBN, Hard Metal <strong>2023</strong> –3<br />

■ Portfolio for automated electrode production ■ Using high performance, high-end tools in mould making ■<br />

■ Lightweight damper system for use in lightweight structures ■ What to expect at EMO ■




18. – 23.09.<strong>2023</strong><br />

EMO<br />

18. – 23.09.23<br />

Hall 11<br />

Booth E34<br />


favorit – The price hit for a large range of applications<br />

S33 with uniLoad – The reasonably priced for individual requirements<br />

S31 with new loading system –The versatile for big tasks<br />

S100 – The perfect machine for the entry-level segment<br />

S131 with roboLoad – The universal machine for a wide range of internal<br />

grinding applications<br />

studer.com/emo<br />

The Art of Grinding.<br />

A member of the UNITED GRINDING Group

editorial<br />

Eric Schäfer<br />

editor-in-chief<br />

The full range…<br />

…awaits visitors to the world’s leading trade fair for production<br />

technology in Hanover. EMO HANNOVER <strong>2023</strong> scores with<br />

a unique range of technology that covers the entire spectrum<br />

of production technology. From machining centers and lathes<br />

to cutting tools and clamping devices to measuring equipment<br />

and control systems. The show covers all the major topics in the<br />

industrial value chain, presenting current state of the art and<br />

possible future scenarios for the coming developments.<br />

It is important for visitors to filter through the innovations and<br />

new developments that can be used to advance their own<br />

manufacturing and production. This issue of hp tooling, with its<br />

extensive EMO section, aims to help. Readers of this issue will also<br />

find in-depth information on the three major trend topics at the<br />

show – digitalization, additive manufacturing and sustainability<br />

in production.<br />

One more word on sustainability: it not only affects production<br />

itself, but starts with the tool used, the coolant used and through<br />

every individual step. Circular economy is the key word. It<br />

can extend the life cycle of products and raw materials to the<br />

maximum, for example by sharing, leasing, recycling, repairing<br />

and refurbishing. When it comes to optimizing production<br />

processes, digitalization – also in combination with artificial<br />

intelligence – leads to higher quality and more cost-effective<br />

products.<br />

Irrespective of the current topics, EMO will show whether the full<br />

range will lead to full order books. Experts are expecting the first<br />

indications of whether or not the currently gloomy global business<br />

outlook in the machine and tool building sector will recover in the<br />

foreseeable future.<br />

Hall 11<br />

Booth C19<br />

Functionally<br />

perfect surfaces<br />

Visit us in hall 11, booth C19 to experience<br />

innovative technologies, solutions and trends around<br />

surface finishing life. Meet our experts and let us<br />

work together on your tailor-made solution.<br />

Be there! We are looking forward to your visit.<br />

Superfinishing<br />

Flat Finishing<br />

Fine Grinding<br />

Double-Disk Grinding<br />

Automation<br />

Service<br />

Retrofitting<br />

Talk to us, and we will<br />

find your solution.<br />

+49 7834 866-0<br />

info@supfina.com<br />

Eric Schäfer<br />

editor-in-chief<br />

Engineering with<br />

High Precision<br />


table of contents<br />

cover story<br />

The perfect connection<br />

Special tools from Horn 6<br />

materials & tools<br />

Even composite materials no problem 9<br />

“Marathon” tools with a license for precision 10<br />

New high performance cutter for the highest demands on productivity 12<br />

The best deep bores with PCD 13<br />

processes<br />

Burrless chamfering with world’s first V-shaped blade 29<br />

Lightweight damper system for use in lightweight structures<br />

Fraunhofer Institute for Manufacturing Engineering and Automation IPA 32<br />

Digital transformation in tooth machining 36<br />

machining center<br />

Opening new industries with a Kern Micro HD around the globe 40<br />

components<br />

A partnership for an automated future 43<br />

When precision is of the essence 44<br />

Strong all-in solution for efficient quality inspections 45<br />

EMO<br />

Digitalization and sustainability 47<br />

Powerful and productive 48<br />

Meeting complex challenges with smart solutions 49<br />

Precise, process-reliable and efficient milling 50<br />

Machining center with tilting table for enhancing precision manufacturing 51<br />

Ready to lead the future of machining solutions 52<br />

Small differences that make a big impact 53<br />

umati is back 54<br />

Manufacture more parts faster 55<br />

Customer care special exhibition area and machine highlights 56<br />

Mechatronic solutions for metal working 57<br />

news & facts 16<br />

fairs 22, 58<br />

impressum & company finder 59<br />

4 no.3, August <strong>2023</strong>

The new eCatalogue <strong>2023</strong><br />

The complete cutting tool solution is now<br />

available in a digital version!<br />

cutting.tools/uk/en/ecatalogue<br />

CERATIZIT is a high-technology engineering<br />

group specialised in cutting tools and hard<br />

material solutions.<br />

Tooling a Sustainable Future<br />


cover story<br />

The perfect connection<br />

Special tools from Horn<br />

It was autumn 1955 and the wind was blowing the last<br />

brown leaves from the trees. As Otto Dunkel watched his<br />

leaf rake doing its job, he had a brilliant idea. That was the<br />

birth of the wire spring contact. Today, ODU GmbH & Co.KG<br />

(Otto Dunkel) is one of the world’s leading companies for<br />

the development and production of connector systems. For<br />

the production of the high-end connectors, the company relies<br />

on precise Swiss-type turning machines and tools from<br />

Paul Horn GmbH. For about 20 years the two companies have<br />

been working together closely, to ensure that the demanding<br />

machining tasks are optimised for producing the perfect connector.<br />

The close partnership will continue, especially with<br />

regard to the machining of lead-free brass and other alloys.<br />

Similar to the individual twigs of his broom, Otto Dunkel<br />

divided the contact surfaces into individual springs, resulting<br />

in a multitude of contact points. The result was a revolution:<br />

constant contact resistance and consistent contact pressure.<br />

With this the weak point of message transmission systems,<br />

namely the unreliable plug-in contact, was finally overcome.<br />

Founded in 1942, the ODU group of companies now<br />

has 2,500 employees worldwide. The headquarters of the<br />

Bavarian company is located about 80 km east of Munich in<br />

Mühldorf am Inn. ODU supplies connector systems, among<br />

others, to the medical industry, the measurement and testing<br />

sector, industrial electronics, the military and the automotive<br />

industry. It is noteworthy that ODU developed the first highcurrent<br />

connectors for electromobility.<br />

For micro-machining and other cutting operations, ODU<br />

relies on tool solutions from Horn and machines from Tornos<br />

The S274 µ-Finish system is efficient for<br />

micro-machining of components<br />

Horn tools<br />

“In the past we often ground tools ourselves for machining<br />

special connectors. However, with quantities of<br />

several hundred thousand per year, we need process-reliable<br />

and productive tooling systems,” says ODU tool manager<br />

Tobias Fuchshuber. “Our cooperation with Horn has existed<br />

for about 20 years.” Horn field service representative<br />

Michael Götze has been involved from the beginning: “During<br />

this extended period we have been able to solve numerous<br />

machining problems at ODU. Its employees are always open<br />

6 no. 3, August <strong>2023</strong>

cover story<br />

The N105 broaching system can be adapted to<br />

many applications<br />

To ensure a good contact, a high surface finish is an<br />

important quality feature of a plug connector<br />

to new tool technologies and we often test new products there<br />

as a result.” ODU relies on numerous Horn tool systems.<br />

“The machining tasks at our company are very diverse. On<br />

more than 175 sliding-headstock lathes we machine micro<br />

components of a few tenths of a millimeter in diameter up<br />

to parts of 0 30 mm”, says Fuchshuber. Tools from Horn are<br />

used in all areas of production. From the µ-Finish system<br />

S274 for sliding-headstock turning of micro components to<br />

internal turning and grooving. At ODU 80 % of the material<br />

processed is brass. Aluminum, copper and stainless steel<br />

account for the remaining 20 %.<br />

It’s the surface that counts<br />

For contacts in particular, high surface quality is a decisive<br />

feature. For turning contact pins, ODU relies in part on the<br />

Horn tool system S274 in the µm finish variant. Grinding a<br />

sharp and almost flawless cutting edge on a tool requires a<br />

lot of know-how. Grinding wheels with the finest grits, special<br />

grinding techniques and a microscope with 400x magnification<br />

are necessary to ensure that the tool performs as<br />

required. Every batch of the µ-Finish system is subject to<br />

100 % inspection. Important criteria for quality assurance are<br />

the high-tolerance surface quality of the rake and flank surfaces,<br />

the center height and especially the sharpness of the<br />

cutting edge. Irregularities on the cutting edge of more than<br />

0.003 mm are considered to be out of tolerance.<br />

For the production of a coupling of a wire spring contact,<br />

Fuchshuber was looking for a new tooling solution. “The<br />

problem with drilling the component is the special shape of<br />

the base of the hole,” explains Fuchshuber. ODU manufactures<br />

the brass component in seven different variants from a<br />

bore 0 of 1.43 mm up to 3.6 mm. “Before we switched to the<br />

Horn tool, we pre-drilled the holes and then bored them out<br />

with a tool we ground ourselves,” says Fuchshuber.<br />

DS cutter of special shape<br />

In series production, however, problems arose due to impeded<br />

chip flow. In addition, there was potential for reducing<br />

the machining time further. With several hundred thousand<br />

parts per year, this was a decisive factor. Horn provided<br />

the solution with the DS milling system with internal coolant<br />

supply. The milling cutters are ground with a special<br />

shape. When plunging into the solid, a hole is produced with<br />

the same shape at the base. All of the seven cutter variants<br />

are ground with sharp cutting edges, which are uncoated.<br />

The changeover to the milling tools resulted in the saving of<br />

one process step and also in an increase in process reliability<br />

due to the controlled chip evacuation. In addition, the cycle<br />

time was significantly reduced. “Conversion of the seven tool<br />

variants only took about twelve weeks. The speed with which<br />

Horn reacts as well as the fast delivery noticeably shorten<br />

the time it takes to change over our machining processes,”<br />

no. 3, August <strong>2023</strong><br />


cover story<br />

The special tool for<br />

broaching the location key<br />

Broaching the location key was a<br />

challenge in the tool design<br />

says Fuchshuber. He relies on<br />

a Tornos DECO 10 sliding-headstock<br />

lathe to produce the component.<br />

Working closely together for 20 years:<br />

Peter Ortmaier, Tobias Fuchshuber and Michael Götze<br />

sources HORN/Sauermann<br />

Further special tools from Horn are<br />

used for machining a casing bushing. For<br />

two axial grooves, Fuchshuber relies on the<br />

Supermini system type 105. The grooves have 0 of<br />

11 mm and 7.7 mm. The special feature is that a thin-wall web<br />

of 0.2 mm must remain between the two grooves. The required<br />

tolerances are very tight. Here, too, a special tool optimised<br />

for machining brass is used. The tool is sharp, uncoated<br />

and has a polished rake face. Inside the turned part, a Supermini<br />

tool broaches a 20 mm long, 1 mm deep,<br />

fail-safe keyway in four strokes. The keyway<br />

ensures that the plug can be pushed into the<br />

socket in one orientation only. At the end of the<br />

groove, an internal recess serves as a relief for the<br />

broaching tool. This component is manufactured<br />

at ODU on Tornos DECO 13 and DECO 20 lathes.<br />

Broaching of a locating key<br />

“We were given the special task of producing a connector<br />

housing. We were required to broach a circular groove,<br />

rather than a linear one. However, a locating key with a width<br />

of 3 mm had to remain within 0 of 13 mm,” explains Götze.<br />

“We previously embossed the key from the outside but wanted<br />

to eliminate this operation,” adds Fuchshuber. The solution<br />

was a broaching tool of oval shape with the form of the<br />

key recessed on one side. During machining, first the inside<br />

is turned so that a ring remains. Then the tool enters<br />

the workpiece and commences the broaching process. Machining<br />

is started at one position. As soon as the diameter<br />

is reached, the spindle turns the workpiece through 90 °, a<br />

process that is repeated four times until the inner diameter<br />

is circular and the locating key remains in the correct position.<br />

The total machining time for the broaching process is<br />

around 20 s.<br />

The successful cooperation between ODU and Horn will<br />

continue to grow ever closer in the future, especially with regard<br />

to the machining of lead-free brass. The elimination of<br />

lead as an alloying element worsens the machinability of the<br />

material. This presents users as well as tool manufacturers<br />

with new difficulties. “Lead-free brass will present us with<br />

new challenges in the productive machining of our components<br />

in the near future. However, with tool partners such as<br />

Horn ready to assist, we see ourselves well looked after in this<br />

area,” says Fuchshuber. EMO <strong>2023</strong>, hall 8, booth A24<br />

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

8 no.3, August <strong>2023</strong>

Even composite materials no problem<br />

materials & tools<br />

Glass, carbon and aramid fibers pose new challenges<br />

for a wide range of industries worldwide.<br />

Tyrolit now presents the comprehensive Tyrolit Power<br />

range for efficient machining.<br />

The leading Austrian company presented its innovative tools<br />

for cutting, grinding, drilling, milling and surface finishing<br />

of the most demanding workpieces made of composite<br />

materials for the first time at JEC World <strong>2023</strong> in Paris,<br />

the global trade fair for composite materials and their<br />

applications.<br />

Low weight, durability and freedom of design are<br />

properties of materials that are normally mutually<br />

exclusive – which is not the case in the composite industry.<br />

The innovative materials are able to withstand high pressure<br />

and at the same time support the trend towards lightweight<br />

construc tion. These complex materials present numerous<br />

industries with new challenges in production. Tyrolit<br />

is the partner for solving new types of problems and<br />

designing innovative production processes together with<br />

their partners.<br />

Thanks to decades of experience in the manufacturing of<br />

grinding tools and numerous collaborations with renowned<br />

machine manufacturers worldwide, the company is able to<br />

provide its customers with economical and sustainable solutions<br />

for the processing of composite materials. They have<br />

been offering high-quality solutions for the surface treatment<br />

of composites since 2017, and this portfolio is now<br />

being complemented by tools for all applications.<br />

Machining of composites with Tyrolit Power<br />

The new Tyrolit Power range is specifically designed for<br />

these difficult-to-machine materials and has been extensively<br />

tested, resulting in highly efficient machining processes and<br />

guaranteeing an unparalleled tool lifetime. Tyrolit’s portfolio<br />

includes products for cutting, grinding, drilling, milling and<br />

surface finishing of the most demanding workpieces with<br />

hand-held machines, semi-automatic robots and on high-tech<br />

CNC machines.<br />

The new assortment offers solutions for every process step<br />

for machining of composite materials and solves known problems.<br />

With Tyrolit Power process reliability in the production<br />

is increased and homogeneous surface results are facilitated.<br />

The machines are equipped with special protective measures<br />

to improve the safety and health of users. The new tools generate<br />

less dust, minimize vibrations during machining and<br />

support ergonomic working. The products are being used in<br />

numerous industries, for example for grinding rotor blades<br />

in the wind power industry, for matting surfaces in the aerospace<br />

industry, and for machining lightweight components<br />

in the automotive industry.<br />

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

from<br />

IGUANA:<br />



ATION BW<br />

INNOV 2021<br />

Innovationspreis Baden-Württemberg<br />


materials & tools<br />

Extensive portfolio for automated electrode production<br />

“Marathon” tools with a license for precision<br />

oil, ideally with internal shaft cooling at the<br />

same time. So surely a combination is out of<br />

the question.<br />

Not necessarily, because in the meantime<br />

there are very good filter systems for liquid<br />

cooling lubricants, making it an interesting<br />

option to wet-mill copper and graphite electrodes<br />

on the same machine. This results in<br />

users achieving maximum flexibility as well as<br />

better utilisation of the machines integrated<br />

into the automated system. In combination<br />

with ZECHA’s highly precise and reliable<br />

milling tools, this enables optimally calculated<br />

and safe production workflows and milling<br />

processes.<br />

Laser sharp and proven in mould making: the IGUANA series from<br />

ZECHA Hartmetall-Werkzeugfabrikation GmbH is the diamond coated<br />

solids carbide milling series with extremely sharp cutting edges and endurance<br />

Consistently high quality and maximum flexibility aren’t only<br />

key features in mould making. Maintaining maximum efficiency<br />

means one has to use high performance, high-end tools.<br />

Because once these are acquired, the next step comes: low manpower, automated<br />

production. Unthinkable? ZECHA Hartmetall-Werkzeugfabrikation<br />

GmbH is banging the drum for mixed machining with an intelligent tool<br />

selection.<br />

The mould making companies’ ability to compete depends completely on<br />

their automation. In addition to machining, this especially includes the clever<br />

connection and coordination of all manufacturing technologies needed for<br />

component production. This includes erosion, laser machining, as well as<br />

component cleaning and measurement. An essential aspect is the milling<br />

of usually very demanding materials – the perfect area of application for<br />

ZECHA Hartmetall-Werkzeugfabrikation GmbH’s high precision micro tools.<br />

It’s all in the mix<br />

At first glance some things just don’t seem to go together: who would ever<br />

think of machining graphite and copper on the same machine? “Most people<br />

immediately dismiss it.” according to Andreas Weck, application engineer at<br />

the company. “But the solution is mixed machining! This is the machining of<br />

different materials that usually aren’t machined with the same cooling lubricant,<br />

in this case combining graphite and copper electrode machining – two<br />

strategies that couldn’t be more different.”<br />

This is because graphite is usually dry milled on specially configured<br />

milling machines with particularly powerful extraction systems and the corresponding<br />

ventilation. Whereas copper is impossible to dry machine and<br />

therefore requires a differently configured milling machine with emulsion or<br />

Laser sharp and high precision<br />

IGUANA cutters are a good fit for all<br />

non-ferrous metals<br />

One tool series has already become the perfect<br />

partner in mould making in a very short time:<br />

the unique IGUANA cutter series. These solid<br />

carbide tools with up to three cutting edges<br />

have a sealed diamond coating resharpened<br />

by laser. Dennis Thiermann, application engineer<br />

at ZECHA, explains: “The coating process<br />

inevitably leads to a cutting edge radius<br />

of the same order of magnitude as the coating<br />

thickness, which can be considerably more<br />

than 0.01 mm. This is reworked by means of<br />

a laser either on the rake and flank surfaces<br />

or only on the flank surface. This gives us<br />

a consistently sharp cutting edge radius of up<br />

to 1 µm. At the same time coating defects, socalled<br />

clusters, are smoothed out.”<br />

Because of their sharp cutting edges,<br />

IGUANA tools have become standard when<br />

machining different materials, such as aluminum,<br />

copper, all types of brass as well as simple<br />

and fiber-reinforced plastics. These tools<br />

are even used in the machining platinum.<br />

In the meantime there are five sub-series.<br />

In addition to the original range layered on<br />

both sides, there are also tools with edge protection,<br />

helix or shank cooling as well as helix<br />

and shank cooling. These tools are available<br />

as ball, torus and end mills, the series with<br />

shank cooling as torus and end mills. Drills<br />

are also available. The new 935 series completes<br />

all of the copper electrode mould making<br />

needs by being available in the usual free<br />

lengths and corner radii.<br />

10 no. 3, August <strong>2023</strong>

materials & tools<br />

A top performance<br />

thanks to the lowest tolerances<br />

In many cases this technology has already been able to increase<br />

process reliability. “Above all, since the tool life and<br />

dimensional accuracy can maintain an excellent level over<br />

extremely long periods, users benefit straight away. In contrast<br />

to PCD tools, which are usually only available with<br />

one cutting edge in small diameters, IGUANA cutters have<br />

up to three cutting edges,” says Mr. Thiermann.<br />

The lowest possible production tolerances, such as an<br />

impressive 2 µm concentricity and form accuracy of +/-<br />

5 µm, optimise quality, especially when finishing fine surfaces.<br />

This often eliminates time-consuming remachining<br />

which in turn reduces process costs. Moreover, there is<br />

an upward trend in overall economic efficiency thanks to<br />

longer tool life and therefore few tool changes.<br />

Further strong tool partners<br />

Despite IGUANA’s strengths in mould making, there are<br />

still a few partners in the ZECHA product range capable<br />

of increasing ones possibilities. These include the graphite<br />

cutters and the steel cutters from the PEACOCK range (including<br />

CBN) and the new QUEEN BEE tools.<br />

PEACOCK tools are the multi-talents for hard and powder-metallurgical<br />

steels up to 70 HRC, such as cold and hot<br />

work steels, PM steels, special alloys or tungsten copper<br />

with more than 50 % tungsten content. There is an extensive<br />

range with mould-optimised total and free lengths.<br />

The F-series enable a very high metal removal rate and the<br />

whole tool series produces excellent surface qualities.<br />

capacity, they can withstand any marathon machining session –<br />

unmanned, overnight or even the entire weekend.”<br />

For hard cases: CBN<br />

Occasionally in mould making, hard and powder metallurgical<br />

steel of up to 70 HRC simply can’t be avoided. This requires<br />

a particularly tough cutting material to withstand the intense<br />

temperatures in the machining process. Cubic crystalline boron<br />

nitride (CBN) is the ideal counterpart for such tough jobs,<br />

as it combines a high hardness and fracture resistance, even in<br />

interrupted cuts, with high thermal and chemical resistance.<br />

“In a way, it’s a trick to heat up the material for machining,<br />

making it softer which leads to longer tool life.,” explains Mr<br />

Thiermann.<br />

At the same time, CBN has a very high density and resistance<br />

to cracking and diffusion. It enables a homogeneous and even<br />

cut, which also contributes to very good surface finishes. Overall,<br />

CBN cutting materials offer high reliability, tool life and<br />

accuracy when machining steels of up to 70 HRC<br />

High performance tool life champions<br />

Not wanting to worry about precision, tool life and quality in<br />

machining processes when mould making, it’s best to use tried<br />

and tested milling tools. In order to get the most in terms of<br />

efficiency, mixed machining and automation solutions show<br />

the road into the future. “And,” as Mr Weck states, “with our<br />

extensive tool portfolio, our tool users are well prepared for<br />

current and future challenges!”<br />

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

The QUEEN BEE 589 series ball and torus cutters<br />

promise process-reliable machining of steels up to 58 HRC,<br />

nickel based alloys, titanium and special materials up to<br />

1,800 N/mm 2 . The cost-optimised specifically for mould<br />

making adapted tools are available 0 0.8 to 12 mm. Solid<br />

tool properties, coupled with the latest coating technology,<br />

increase tool life and minimise tool changes. Furthermore,<br />

you get very smooth surfaces and less material adhesion.<br />

Maximum precision and cutting quality<br />

Both tool concepts, PEACOCK and QUEEN BEE, combine<br />

the performance potential of the latest solid carbide grades<br />

with finely tuned tool geometry and state-of-the-art PVD<br />

coating. The carbide offers a high level of hardness and<br />

toughness at the same time, making it very stable. Thanks<br />

to their optimised micro-geometry, these tools achieve low<br />

cutting forces and a smooth cut. The coatings possess an<br />

impressively smooth and homogeneous surface, temperature<br />

resistance, strength and damping, as well as the best<br />

possible coating adhesion.<br />

Thanks to the lowest manufacturing tolerances, a concentricity<br />

of 3 µm and a shape accuracy of +/- 5 µm, these<br />

series are particularly interesting for finishing fine surfaces.<br />

Andreas Weck: “Both are perfectly suited for wet and<br />

dry milling. This makes them the perfect choice for mixed<br />

machining, automation and demanding applications with<br />

long running times. Thanks to their high mechanical load

materials & tools<br />

New high performance cutter for the<br />

highest demands on productivity<br />

The new HPC milling cutters from LMT Tools enable maximum metal removal rates<br />

and the highest dimensional accuracy with first-class surface quality<br />

LMT Tools is one of the most renowned experts in<br />

the development and production of precision tools,<br />

and sets regularly technological trends in the market<br />

with its high innovative strength and tool expertise.<br />

The latest coup: new high-performance milling cutters<br />

for high-performance cutting.<br />

The HPC family combines the proven DHC Premium, DHC<br />

INOX Premium, DHC Slot and DHC Hardline tool series<br />

and, thanks to improved technology, achieves a significantly<br />

higher metal removal rate. Considerable increases in productivity<br />

with optimum process reliability are thus guaranteed.<br />

High performance cutting (HPC milling) requires highperformance<br />

tools that can optimally withstand the strains<br />

caused by the high cutting speed and feed rates involved in<br />

the process and ensure cutting with as little vibration as possible.<br />

With the new HPC family, the tool expert offers the perfect<br />

solution. The cutting geometry, coating and cutting-edge<br />

treatment have been specially adapted to the special requirements<br />

of high-performance machining and enable maximum<br />

metal removal rates and high dimensional accuracy with<br />

first-class surface quality. The unequal pitch ensures maximum<br />

smoothness and process reliability, while the surface<br />

quality of the machined workpieces is a further advantage.<br />

The optimum high performance cutter<br />

for every material<br />

Whether trochoidal, side, corner and groove milling or ramps<br />

up to 0 0.5x – the HPC family is designed for a wide range<br />

of applications. There are four versions available: HPC P,<br />

HPC M, HPC UNI and HPC H. The HPC P is the specialist<br />

for higher alloyed steels and castings with a tensile strength<br />

of 900 N/mm 2 or higher. An edge protection bevel reduces the<br />

load on the cutting edge and ensures optimal performance in<br />

the demanding machining of abrasive materials. The HPC M<br />

excels in the machining of austenitic steels, non-ferrous<br />

metals and titanium. The positive cutting-edge geometry and<br />

special coating ensure efficient machining of materials that<br />

usually have higher toughness and are therefore difficult to<br />

machine.<br />

The HPC UNI is a three-flute cutter (all other variants being<br />

four-flutes) and therefore provides a larger chip space.<br />

With excellent chip removal, it is ideally suited for full slot<br />

milling in a variety of materials (P, M, K, N and S). Each flute<br />

has a different helix angle. The HPC H is the best choice for<br />

hardened steel up to 55 HRC. Its targeted edge rounding results<br />

in a particularly stable cutting-edge, allowing for very<br />

high feeds in hardened and high-strength materials up to<br />

1,600 N/mm 2 .<br />

Maximum tool life and productivity<br />

The new HPC family replaces the well-known DHC family.<br />

By optimizing production processes and using state-of-theart<br />

technology, tool life and productivity have been significantly<br />

increased compared to the previous series. “With our<br />

new high performance cutters, high cutting speeds and feeds<br />

can be achieved, resulting in high chip volume and increased<br />

productivity,” says Marcus Paul, global head of product management<br />

and emphasizes: “Compared to the previous families,<br />

we have managed to increase the metal removal rate by<br />

more than 30 % and achieve a tool life increase of up to 70 %.”<br />

Proving the technological leadership of the tool experts.<br />

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

12 no.3, August <strong>2023</strong>

The best deep bores with PCD<br />

materials & tools<br />

When the Schlote Group built a new factory in<br />

Harzgerode in 2017, it was designed to mass produce<br />

only a single part. MAPAL supplied all the cutting<br />

tools. By optimising the tools, the foundation has now<br />

been laid for a future with new products.<br />

Schlote’s story begins in 1969 as a small workshop in<br />

Harsum, where the company is still headquartered. Today<br />

eleven companies with 1,800 employees belong to the Group.<br />

The OEM has eight factories in Germany as well as further<br />

manufacturing facilities in the Czech Republic and China.<br />

Schlote Group customers include big car manufacturers, system<br />

integrators and foundries. Schlote’s turnover stems from<br />

engines (55 %), transmissions (39 %) and chassis (6 %).<br />

Already at other sites a successful cooperation with<br />

Trimet Aluminium existed, manufacturing finished car components<br />

from cast blanks. The awarding of a contract for a<br />

component by a major OEM, involving very high quantities,<br />

led to a joint venture between Schlote and Bohai Trimet in<br />

Harzgerode.<br />

Stefan Frick (left) and Sebastian Swiniarski<br />

inspect a finished clutch housing<br />

Milling competence<br />

right down the line<br />

■ 45° Milling - Smooth cut and high metal<br />

removal at extremely smooth running<br />

■ 90° Milling - Highest productivity, cost<br />

reduction and optimal distribution of cutting<br />

force<br />

■ HFC-Milling - High metal removal under the<br />

most difficult conditions<br />

■ 3-D Milling - Universal applicable tool<br />

system for mould and die<br />

■ Solid carbide milling - Over 1000 products<br />

for every application<br />


materials & tools<br />

More than 4,000 clutch housings<br />

per day<br />

The part being manufactured in Harzgerode<br />

is a clutch housing made of die-cast aluminum.<br />

A single version of the automatic transmission<br />

is being delivered to various major car<br />

manufacturers, where they are predominantly<br />

installed in vehicles with two-liter engines.<br />

The bell housing connects the transmission to<br />

the engine. While the transmission side is the<br />

same on all the clutch housings, the other side<br />

is adapted to the respective car manufacturer’s<br />

engine. The differences are mostly small,<br />

so the bell housing construction is 99 % identical<br />

for all of the car manufacturers.<br />

A manufacturing cell at Schlote is made up of three machining centers from<br />

SW; two W06 double-spindle machines and a one6 single-spindle machine<br />

Schlote Harzgerode GmbH is currently producing<br />

4,000 parts per day. At over 80 % the<br />

modern factory exhibits a very high degree<br />

of automation. Five days a week around the<br />

clock 120 employees work at the Harzgerode<br />

site. Production can be expanded to six or<br />

seven days a week if need be.<br />

As is the case for the entire automotive industry,<br />

the requirements placed on parts are<br />

very high here. “The part is not only an adapter<br />

flange, but also the back of the transmission.<br />

The bearing seats thus require the highest<br />

degree of precision”, explains Sebastian<br />

Swiniarski, work preparation team lead at<br />

Schlote. The part requires many bores with<br />

different tolerances, whereby precision manufacturing<br />

is needed down to the thousandth of<br />

a millimeter.<br />

Deep drilling is one of the machining steps that takes place on the<br />

double-spindle machine; bores 180 mm and 141 mm deep are created<br />

with an 8 mm drills from MAPAL<br />

The first machining steps for the clutch housings occur on<br />

double-spindle machines; while machining takes place at the back,<br />

new parts can already be clamped at the front<br />

MAPAL and Schlote can look back on<br />

many years of effective cooperation. MAPAL<br />

is therefore entrusted with supplying PCD<br />

milling cutters (which create the defined<br />

rough surfaces on which sealant is applied),<br />

tap drills, reamers and an array of diverse<br />

drilling tools. “We offer our customers comprehensive<br />

solutions including the development<br />

of entire processes”, says Stefan Frick,<br />

MAPAL’s technical advisor to Schlote.<br />

Successful improvement process<br />

From the very beginning on a watchful eye<br />

was kept on the implemented tools. Since<br />

Harzgerode went into operation, analyses<br />

have been performed continuously to find<br />

possible weak points and optimise manufacturing.<br />

Within the context of this continuous<br />

improvement process, Schlote and MAPAL<br />

have managed to achieve longer tool lives,<br />

lower tool expenditures and higher production<br />

quantities over years. While 3,600 parts<br />

per day were produced at most in the beginning,<br />

the limit has now been raised to 4,500<br />

parts –without needing more machines.<br />

14 no. 3, August <strong>2023</strong>

materials & tools<br />

The newest optimisation involves deep drilling for oil<br />

channels used to change gears in the automatic transmission.<br />

“We evaluate every month with our tool management<br />

system which tools have to be exchanged how often”,<br />

Swiniarski reports. “Time and again the deep drills have<br />

proven to be particularly sensitive. As these drills are<br />

relatively cost intensive, we have concentrated on them<br />

to further cut our tool costs.” Quality aspects are also inherent<br />

in tool wear as a blunt drill produces burrs at the<br />

bore exit.<br />

In this particular case, two of five deep bores are involved<br />

with a 0 of 8 mm and cutting depths of 180 mm and 141 mm.<br />

They run through the part from the side up to the bearing<br />

seat in the middle. Up to now solid carbide tools were used<br />

for this, which is standard for deep bores. Schlote was able<br />

to achieve a tool life of 2,500 parts in this way. The load<br />

monitoring of the machine already registered tool wear<br />

starting at 2,000 parts though, and burrs could be seen at<br />

the bore exit.<br />

Significantly longer tool life with PCD<br />

When it came to optimising the deep bore, plant manager<br />

Tino Lucius, a former MAPAL employee, suggested PCD<br />

variants. And so the partners developed the idea of deploying<br />

a PCD tip for the deep drills. There was a lot to consider<br />

during the implementation, Frick relates: “It is not possible<br />

to construct this type of drill entirely out of PCD. Apart<br />

from the high costs, the brittleness of the material is a problem.<br />

There is also always the danger of chipping of the cutting<br />

edges during interrupted cuts. Good cooling must also<br />

be ensured as PCD is heat sensitive.”<br />

For the new tool MAPAL started with the existing solid<br />

carbide drill and inserted a PCD cutting edge at its tip. The<br />

structure of the tool is reminiscent of a concrete drill with<br />

a carbide tip. The manufacturers in Harzgerode are very<br />

happy with the PCD deep drill’s tool life. While the solid<br />

carbide drill’s tool life ends after 2,500 parts, the PCD<br />

version keeps going reliably up to 15,000 parts. There is<br />

further scope for improvement in machining challenges,<br />

such as blowholes in the material and varying casting<br />

quality. The partners are currently working on this together.<br />

“We have occasionally been able to achieve a tool life of<br />

40,000 parts. Naturally, we want to make this ultra-long tool<br />

life the norm”, Frick stresses.<br />

The future is electric<br />

Clutch housing manufacturing at the site was planned to last<br />

at least eight years with a peak output of 1.1 million parts<br />

per year. This peak was surpassed in 2020. Production has<br />

been ongoing for five years in the meanwhile with 900,000<br />

parts produced per year.<br />

Due to continuously improved productivity and the lower<br />

production quantities, there has been time to address future<br />

trends and produce different parts. The factory is already being<br />

modified for this purpose. The first of two new projects<br />

involves six different parts that Schlote is to produce for a<br />

hybrid model of super sports car manufacturer.<br />

In the other project Schlote’s expertise as a clutch housing<br />

manufacturer is once again called for – this time for an electric<br />

car. Schlote draws from the trend toward electric mobility<br />

by supplying e-cars with transmissions as well.<br />

For an innovative model with three gears, the connection<br />

between engine and transmission is to be produced in<br />

Harzgerode. Half of the factory capacity is currently being<br />

converted. The production of parts for combustion engines<br />

is to be ramped down to 50 %. In future hybrid cars<br />

will account for 10 % and purely electric mobility for 40 %.<br />

Schlote has already produced the first parts for the new<br />

projects.<br />


kapp-niles.com<br />

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

The cutting data is the same as that of the solid carbide<br />

drill at a spindle speed of 8,700 rpm, a feed of 0.3 mm/rev and<br />

a cutting speed of 218 m/min. The new drill’s potential lays in<br />

its considerably longer tool life, the resulting lower tool costs<br />

and the higher process reliability. Less tool changes also<br />

means less machine downtime.<br />

Production at Schlote in Harzgerode involves a total of<br />

ten manufacturing cells. Each cell is made up of three machines<br />

from the manufacturer SW, two W06 double-spindle<br />

machines and a one6 single-spindle machine. The parts are<br />

machined in three clamping setups, whereby the doublespindle<br />

machines handle the first two setups and finishing<br />

takes place during the third.<br />

Hall 11<br />

Booth E06

news & facts<br />

HELLER continues to invest in Changzhou<br />

Production site to be significantly expanded<br />

Recognising the importance of the large Chinese market,<br />

HELLER has recently invested in its Changzhou<br />

plant, creating the conditions to produce more than<br />

100 machines per year on site. In the presence of local<br />

politicians, numerous key customers and the HELLER<br />

management, the extension building was officially<br />

inaugurated June 16, <strong>2023</strong>.<br />

As far back as the 1950’s, HELLER was already looking far<br />

beyond its European home market to China. The managing<br />

directors at the time made important contacts and began<br />

manufacturing machine tools for the local market. This<br />

led to several close collaborations with local distributors. The<br />

company was poised for growth, so in 2013 the Nürtingenbased<br />

machine tool manufacturer set up its own subsidiary<br />

in Changzhou, which is located in the center of the Yangtze<br />

Delta. At that time, a 7,000 m 2 service and assembly plant was<br />

built on a total area of 24,000 m 2 .<br />

Since then business has picked up strongly. In the beginning<br />

mainly with well-known companies in the commercial<br />

vehicle industry. Since the early 2020’s, HELLER has also<br />

increasingly won customers from the sectors of aerospace,<br />

mechanical engineering, hydraulics etc. For several years<br />

now the German company has been producing the universal<br />

machines required by these industries locally in Changzhou.<br />

This proved a crucial step because, according to Claude<br />

Ballay, general manager of HELLER China, experience shows<br />

very clearly that ‘local for local’ production is becoming increasingly<br />

important in the Chinese market. He explains:<br />

Regional machining center business in China is growing;<br />

currently HELLER China mainly produces the 4-axis<br />

H 6000 and the 5-axis HF 3500 and HF 5500 models;<br />

the H 4000 and H 8000 machining centers and the<br />

CBC 200 coating modules are also built here as needed<br />

HELLER China has invested in its local subsidiary in<br />

Changzhou, China, expanding its production and<br />

service floorspace from 7,000 m 2 to 9,000 m 2<br />

“Delivery times of three to four months are expected here<br />

and we have to be able to meet them reliably. What’s more,<br />

our customers understandably expect us to produce much of<br />

what we sell here in the country.”<br />

Accordingly HELLER began building its first machining<br />

centers for the so-called regional market four years ago. Local<br />

suppliers were contracted and in-house staff trained for<br />

assembly and ongoing quality control. The new strategy began<br />

to pay off very quickly. In spite of the Covid dip, business<br />

in the universal machine market in particular has grown and<br />

now accounts for almost half of total sales in China.<br />

New building adds 2,000 m 2<br />

In line with the ‘local for local’ strategy of the Chinese universal<br />

machine business, the management of the HELLER<br />

Group decided at the end of 2021 to expand the Changzhou<br />

plant. Construction began in the spring of 2022, and about a<br />

year later the new 2,000 m 2 building was completed and inaugurated<br />

June 16, <strong>2023</strong> in the presence of 30 VIP customers,<br />

local politicians and the HELLER management.<br />

A total of 9,000 m 2 of production floorspace is now available.<br />

The expansion has been key in enabling the company<br />

to produce a greater volume of machines in an efficient and<br />

cost-effective manner.<br />

further information: www.heller.biz<br />

16 no.3, August <strong>2023</strong>

news & facts<br />

HELLER cooperates with<br />

Porsche Penske Motorsport<br />

HELLER is now the new technology partner of Porsche<br />

Penske Motorsport. The cooperation was visible for the<br />

first time at the legendary 24 hours of Le Mans on June<br />

10 th and 11 th , <strong>2023</strong>.<br />

“HELLER and Porsche share the same values: precision in<br />

detail and sustainability in development and production,”<br />

describes HELLER CEO Dr. Thorsten Schmidt the new partnership.<br />

And Thomas Laudenbach, vice president of Porsche<br />

Motorsport, adds: “We want to bring innovative technologies<br />

and sustainability to motorsports and be at the forefront of<br />

new developments.”<br />

As part of the cooperation, the company based in Nürtingen<br />

will now work very closely with Porsche Motorsport and<br />

the entire technology network. “In this way we are expanding<br />

our customer potential and can accelerate our growth in<br />

world markets,” CEO Dr. Thorsten Schmidt is looking forward<br />

to the cooperation.<br />

With the newly developed endurance racing car Porsche<br />

963, Porsche Penske Motorsport is embarking on a historic<br />

year in motorsports. This is because the legendary race in<br />

Le Mans took place for the 100 th time this year. Further appearances<br />

in the WEC racing series will follow, including<br />

in Italy (Monza) and Japan (Fuji). And always there: the<br />

HELLER brand logo clearly visible on the Porsche 963.<br />

Furthermore, Porsche Penske Motorsport is showing its<br />

colors on the important US market for HELLER: the team is<br />

also participating in the famous IMSA racing series, which<br />

includes appearances on famous tracks such as Daytona or<br />

Indianapolis.<br />

Both partners are planning numerous events for HELLER<br />

customers. For example, the Porsche 963 will be seen at important<br />

industry fairs at the HELLER booth.<br />

As a celebration of the 100 th 24-hours of Le Mans, Porsche<br />

Penske Motorsport took part with a special and festive<br />

livery. Due to its colorful design, the Porsche 963 was given<br />

the name: “Butterfly”.<br />

further information: www.heller.biz<br />

KENOVA set line V346<br />

Precision and robustness<br />

for Smart Production<br />



Hall 4, Stand B53<br />

• Tool presetter with software EASY<br />

• CNC-spindle autofocus<br />

• Mechanical tool clamping<br />

• CMOS-Camera repeatability ±2 µm<br />

• Tool Holder SK 50 with integrated calibration balls<br />

• An exceptionally quiet servo motor<br />

• Thermo-label printer<br />

QR-Code: scan and<br />

watch product video<br />

KELCH GmbH · Werkstrasse 30 · 71384 Weinstadt<br />

Tel.: +49 (0)7151/20522-0 · info@kelch.de · www.kelch.de

news & facts<br />

EMAG starts construction of a new plant in Mexico<br />

On June 19, <strong>2023</strong>, the symbolic groundbreaking ceremony took<br />

place for the new plant of the EMAG Group in the San Isidro<br />

Business Park in Querétaro, Mexico. This marks the start of an ambitious<br />

investment program of the EMAG Group in the region.<br />

In the last decade the Mexican market has developed into an attractive<br />

production location for the USMCA (“United States Mexico Canada<br />

Agreement”) free trade zone, formerly NAFTA. This is due to several factors:<br />

the strategic location, attractive framework conditions for investment,<br />

a high level of training, a solid infrastructure and a long tradition in<br />

manufacturing.<br />

The symbolic groundbreaking ceremony for the new plant of the EMAG Group<br />

took place in the San Isidro Business Park in Querétaro, Mexico<br />

The global crises of recent years have led to<br />

a rethinking of the value chain and production,<br />

towards so-called nearshoring. Mexico<br />

has benefited from these crises and the misalignments<br />

of production. Industries such as<br />

automotive, aerospace, electronics and consumer<br />

goods are investing billions in existing<br />

and new production capacities.<br />

But Mexico is not just an extended workbench.<br />

Thanks to its good level of education,<br />

the country is home to more and more<br />

research and development sites of global<br />

companies. Against the background of this<br />

dynamic development and ever shorter investment<br />

cycles, the construction of the new<br />

EMAG plant is another step in the company’s<br />

20-year success story in Mexico. In the future<br />

the expansion of local competence and value<br />

creation will be of great importance.<br />

Since entering the market in 1997, EMAG<br />

has continuously invested in its presence in<br />

Mexico. After establishing a branch in Mexico<br />

City in 2003, a new headquarter was opened<br />

in Querétaro in 2015 with a production<br />

area of 420 m². EMAG Mexico was awarded<br />

Supplier of the Year in 2010 (AAM) and 2016<br />

(Sisamex) and was able to realize its first turnkey<br />

project in 2019.<br />

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

MAPAL moves into new building in Komorniki<br />

MAPAL Narzędzia Precyzyjne (MAPAL precision tools) in Poland got a new head office. MAPAL acquired a<br />

5,000m 2 premises in Komorniki, not far from the previous site in Poznań. A modern and generously equipped<br />

office building has now been erected there, the grand opening was in March 29, <strong>2023</strong><br />

In Poland the company serves the production<br />

plants of international automotive and<br />

mechanical engineering manufacturers<br />

among others. A collaboration with the commercial<br />

agency Gallo-Ex in Poznań that began<br />

in 1996 led to its takeover in 2002. Since 2005<br />

the branch office has been trading as MAPAL<br />

Narzędzia Precyzyjne. In 1997 MAPAL received<br />

a major order in Poland from a diesel<br />

engine manufacturer in Tychy, and in 2004<br />

it took on its first tool management project<br />

for the VW plant in Poznań. MAPAL’s reamers<br />

entered the Polish market as far back as<br />

the 1970’s. At that time the buyer was one<br />

of the largest ship engine manufacturers in<br />

the country.<br />

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

18 no.3, August <strong>2023</strong>

news & facts<br />

Platinum Tooling<br />

now represents<br />

Henninger<br />



ROCKS<br />


EMO<br />

Hannover<br />

18. - 23.09.<strong>2023</strong><br />

Stand No. D82<br />

Hall 4<br />

Platinum Tooling, the importer of live tools,<br />

angle heads, marking tools, Swiss tools and<br />

multiple spindle tools manufactured by various<br />

global suppliers, is now importing Henninger<br />

Speed Increasers for North America. The announcement<br />

was made by company president,<br />

Preben Hansen, at headquarters in Prospect<br />

Heights, Illinois, near Chicago.<br />

Henninger is a manufacturer of specialized equipment<br />

and precision machine tool accessories. Spindle speeder<br />

types including mechanical, air and electric motor<br />

driven styles are all available.<br />

These speed increasers help maximize productivity by<br />

achieving a higher spindle rpm that is required for certain<br />

applications in today’s marketplace. Small diameter<br />

tools require rpms that are sometimes not possible<br />

to reach with existing machine tools. In addition they<br />

allow for less wear and tear on the machine’s spindle<br />

when it is not required to run at its maximum rpm.<br />

Mechanical speeders are available with up to a 1:8 gear<br />

ratio and a maximum speed of 50,000 rpm. Air speeders<br />

can run continuously at up to 80,000 rpm and high<br />

frequency motor spindles can maintain up to 80,000 rpm<br />

with high torque, and have variable speed options.<br />

Many of the speeders have automatic tool change<br />

capabilities and are modular in design to offer the customer<br />

greater flexibility. Henninger also manufactures<br />

custom angle heads, live centers, face drivers, and live<br />

chucks. In addition Henninger is the premier manufacturer<br />

for center grinding machines.<br />

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


news & facts<br />

ARCH Cutting Tools acquires VR Wesson<br />

ARCH Global Holdings LLC Company (ARCH) announced the acquisition<br />

of VR Wesson, a manufacturer of standard and special inserts,<br />

tool holders and milling cutters located in Cape Coral, Florida.<br />

The company will join ARCH Cutting Tools, a division of ARCH and<br />

industry-leading, American manufacturer of solid round and indexable<br />

metal removal tooling.<br />

ARCH Cutting Tools is headquartered in Bloomfield Hills, Michigan, and<br />

serves the medical, aerospace, defense, automotive, energy, agriculture and<br />

general industrial markets. ARCH Cutting Tools has facilities across the<br />

Eastern U.S. and is dedicated to engineering high-performance standard<br />

and custom tools that increase efficiencies for end-users. VR Wesson will be<br />

consolidated into ARCH Cutting Tools – Orchard Park, and will expand the<br />

company’s existing insert offering via ARCH Specials.<br />

“ARCH Cutting Tools is proud to announce<br />

the acquisition of VR Wesson, whose<br />

advanced manufacturing technologies and<br />

key accounts will be consolidated into our<br />

Orchard Park, New York facility,” said<br />

Robert Gralke, president of ARCH Cutting<br />

Tools –Orchard Park in Buffalo.<br />

“We are particularly excited to bring laser<br />

PCD finishing capabilities under our roof,<br />

which will increase our team’s efficiencies and<br />

expand our product offering to key industries,<br />

including automotive and medical.”<br />

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

Boehlerit Oberkochen celebrates its<br />

25 th company anniversary<br />

At the end of June the carbide pioneer Boehlerit from Kapfenberg/<br />

Austria celebrated the 25 th anniversary of its German production<br />

company in Oberkochen. As part of the celebrations a tribute was<br />

also paid to long-serving employees.<br />

Cutting material and tool specialist Boehlerit ensures process reliability and<br />

efficiency worldwide with cutting materials, semi-finished products and precision<br />

tools as well as tool systems for milling, turning, drilling and forming.<br />

The company, which was founded in 1932 and has been family-run since<br />

1991, is part of the Brucklacher Group, which Boehlerit forms together with<br />

the two other legally independent sister groups – Leitz and Bilz. The Boehlerit<br />

Group employs over 800 people worldwide at three production sites and<br />

international sales companies.<br />

The Oberkochen production site, which specialises in the manufacture of<br />

high-quality wear products, celebrated its 25 th anniversary June, 30, <strong>2023</strong><br />

with its workforce and numerous invited<br />

guests. The high technical requirements and<br />

the tight deadlines of the tool manufacturer<br />

Leitz from Oberkochen to deliver profile tools<br />

for hard machining express in a maximum of<br />

five days led to the establishment of the carbide<br />

production in Oberkochen in 1998.<br />

Boehlerit now has had one of its production<br />

sites in Oberkochen for a quarter of a century<br />

and has built up an outstanding reputation for<br />

its high-quality products.<br />

The celebration took place in the festively<br />

decorated Ölweihersaal at the Leitz company<br />

and gave the guests the opportunity to experience<br />

the history and development of the<br />

company first hand. The sales manager of<br />

Boehlerit Germany, Mr. Thomas Renfordt,<br />

welcomed the guests. In his speech the managing<br />

director of Boehlerit, Mr. Johann Werl<br />

from Kapfenberg, emphasised the significance<br />

of the anniversary and highlighted historical<br />

aspects. At the same time he underlined<br />

Boehlerit’s future viability in his outlook. The<br />

company plans to further expand its position<br />

in the market and offer new innovative solutions<br />

for the industry. With a strong team and<br />

a clear vision Boehlerit is ready to successfully<br />

shape the next 25 years.<br />

The chairwoman of the supervisory board<br />

and shareholder, Dr. Cornelia Brucklacher, expressed<br />

her sincere thanks to all who are or<br />

have been involved in the success of Boehlerit<br />

up to this date and wished the company continued<br />

success and innovative strength.<br />

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

20 no.3, August <strong>2023</strong>

Another crucial step towards becoming<br />

carbon neutral by 2025<br />

news & facts<br />

CERATIZIT, part of the Plansee Group, has achieved<br />

a major milestone on its journey to becoming carbon<br />

neutral by 2025. Since the beginning of <strong>2023</strong>,<br />

production operations for the carbide specialist<br />

have been powered by over 99 % green energy from renewable<br />

sources.<br />

As part of an ambitious sustainability strategy,<br />

CERATIZIT has been gradually switching to renewable energy<br />

sources for energy needs at its production sites. Now 99 %<br />

of CERATIZIT’s energy requirements come from renewable<br />

sources – a claim that is backed up by corresponding certificates<br />

from its energy suppliers. As such, the carbide specialists<br />

have reached their first milestone on the path to becoming<br />

carbon neutral by 2025. Switching the majority of its<br />

energy supply to renewable sources has helped the company<br />

immediately cut its corporate carbon footprint (CCF) by<br />

over 20 %.<br />

Fixed calculation basis for carbon-cutting targets<br />

The company has based its carbon-cutting targets on the figures<br />

from its 2020/2021 business year, in which CERATIZIT<br />

emitted almost 176,000 metric tons of CO 2 e (carbon dioxide<br />

equivalent) according to the GHG protocol (Greenhouse<br />

Gas Protocol). Around a quarter of the company’s emissions<br />

fall under scope 1 of the protocol (direct GHG emissions) and<br />

a quarter from scope 2 (electricity indirect GHG emis sions),<br />

while around half fall under scope 3, which stem in particular<br />

from purchased goods and services as well as employees’<br />

trips to and from work.<br />

“With these final figures we have the necessary information<br />

to take the first steps to reducing our carbon footprint.<br />

Switching to renewable energy is only the first step in this<br />

process, but one that has enabled us to reduce our footprint<br />

by more than 20 %,” explains executive board spokesperson<br />

Andreas Lackner. With the figures now available the company<br />

will decide on further measures to be taken over the next<br />

few months to reduce the company’s corporate carbon footprint<br />

(CCF) by at least 35 % as currently planned by 2025.<br />

The company has set itself the target of reducing its<br />

2020/2021 CCF levels by 60 % through additional measures<br />

by 2030, such as switching to ‘green’ hydrogen. The company<br />

plans to achieve ‘net zero’ by 2040, ten years ahead of the<br />

targets specified under the Paris Agreement.<br />

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

Precise and<br />

productive<br />

CBN profile grinding discs<br />

Liebherr-Verzahntechnik GmbH<br />

EMO: September 18-23<br />

Hall 11, Booth F37<br />

One-, two- or three-ribbed CBN profile<br />

grinding discs for internal gears<br />

– High-quality internal gears for low-noise use in gearboxes<br />

– Increased load capacity due to the high residual<br />

compressive stresses with CBN grinding<br />

– Individual grain sizes for different applications<br />

– Shorter grinding times<br />

– Roughing and finishing in a single process<br />

– Longer tool life<br />

– Time-consuming dressing not necessary with CBN tools<br />

Liebherr-Verzahntechnik GmbH, tools.info@liebherr.com, www.liebherr.com

news & facts<br />

fairs<br />

5 th leading trade fair for deburring technology<br />

and precision surface finishing<br />

Whether the mobility and energy transition, sustainability, health<br />

or safety is involved – global megatrends have a profound effect on<br />

industrial production. They’re also impacting demands placed on<br />

burr-free components, as well as cleanliness and surface finishing<br />

quality. As the only international trade fair for deburring technologies<br />

and precision surface finishing, DeburringEXPO presents corresponding<br />

offerings in a concentrated fashion which is unparalleled<br />

by any other event.<br />

The bilingual expert forum and various theme parks will also ensure an<br />

effective transfer of knowledge at the 5 th leading trade fair at the Karlsruhe<br />

Exhibition Center October, 10 th to 12 th , <strong>2023</strong>.<br />

Ultrasonic deburring takes place in a water basin in which components<br />

are advanced to the high-frequency ultrasonic sonotrode<br />

image source: ultraTEC<br />

The right process for every application<br />

“Thanks to its multi-industry, multi-material focus, DeburringEXPO supports<br />

companies from all industry sectors in their search for suitable processes,”<br />

reports Gitta Steinmann, project manager at private trade fair promoters<br />

fairXperts GmbH & Co. KG. “The entire spectrum of technologies,<br />

processes, tools and services for deburring, edge rounding, cleaning and<br />

surface finishing are presented. The strengths and the limits of various processes<br />

ranging from mechanical deburring with tools to vibratory grinding,<br />

brush deburring and blasting with solid and liquid media, right on up to ma-<br />

chining with special technologies, can be discussed<br />

directly on site.” The latter includes, for<br />

example, ultrasonic deburring which makes it<br />

possible to selectively deburr edges and crossdrilled<br />

holes in a fully automated, verifiable<br />

process. Since this energy-efficient process can<br />

be used for nearly any material, the range of<br />

workpieces covers everything from micro parts<br />

for the optics and watchmaking industries to<br />

precision tools for machining, all the way up<br />

to components used in machinery and vehicle<br />

manufacturing weighing 15 kg.<br />

Abrasive flow machining (AFM) also covers<br />

a very broad range of applications. It’s used<br />

for the deburring, edge rounding and polishing<br />

of components in the automotive and aviation<br />

industries, as well as in energy technology,<br />

fluid and medical engineering, extrusion<br />

technology and mould and tool making. The<br />

strengths of this process result from its ability<br />

to machine internal areas and surfaces which<br />

are difficult to access, for example in additively<br />

manufactured components.<br />

In the case of ECM (electrochemical machining),<br />

the machining process is based on<br />

the anodic dissolution of the respective metal.<br />

Nearly all metals can be machined, in particular<br />

high-alloy materials such as nickelbased<br />

and titanium alloys, and hardened materials.<br />

In addition to deburring, selective<br />

edge rounding and polishing, the technology<br />

is also used for contouring and shaping components,<br />

as well as for burr-free drilling – for<br />

example in the aviation and aerospace industry,<br />

the automotive and toolmaking sectors, in<br />

medical, microsystems and energy technology.<br />

Laser deburring is an effective method for<br />

removing fine burrs and flakes from the outer<br />

contours of very delicate, thin-walled workpieces.<br />

Even the edges of drill-holes with diameters<br />

of just a few tenths of a millimeter<br />

can be machined. The process is also distinguished<br />

by very high processing speeds.<br />

Thermal energy machining (TEM) permits<br />

the simultaneous removal of external<br />

and internal burrs by means of vaporisation.<br />

It’s used primarily for metal workpieces such<br />

as hydraulic manifolds, and for components<br />

made of thermoplastics from which internal<br />

and external burrs have to be removed – even<br />

from very difficult to access places.<br />

further information: www.deburring-expo.de<br />

22 no. 3, August <strong>2023</strong>

symposium<br />

news & facts<br />

VDW symposium<br />

attracted attention<br />

in Vietnam<br />

The VDW (German Machine Tool Builders’ Association),<br />

Frankfurt am Main, staged its third symposium<br />

in Vietnam’s capital Ho Chi Minh City June 12<br />

to 14, <strong>2023</strong>. Ten German manufacturers showcased<br />

innovations in manufacturing technology – machine<br />

tools from Germany.<br />

“The Vietnamese market has been enjoying very strong<br />

growth recently, and we are now the fifth-largest supplier<br />

here. And so it is only logical for our industry to return<br />

here in person to attract more attention,” says Gerda<br />

Kneifel, VDW ambassador at the symposium in Ho Chi<br />

Minh City. Ten German manufacturers were on hand at the<br />

event: Alzmetall Werkzeugmaschinenfabrik, Altenmarkt,<br />

the Chiron Group, Tuttlingen, Gleason Corporation,<br />

Ludwigsburg, Grob-Werke, Mindelheim, Maschinenfabrik<br />

Berthold Hermle, Gosheim, Index-Werke, Esslingen, Open<br />

Mind Technologies AG, Wessling, Röders GmbH, Soltau,<br />

Siemens AG, Munich, and the Trumpf Group, Ditzingen.<br />

They presented their latest machines, solutions and services<br />

for Vietnam. 121 participants from the most important<br />

customer industries– the electronics, textile and food industries<br />

as well as the metal production and processing sectors<br />

– accepted the invitation of the VDW and the German--<br />

Vietnamese Chamber of Foreign Trade. Being the best response<br />

since the first Vietnam symposia was held in 2016.<br />

“We need to raise the efficiency of our machines, and automation<br />

is a further very important aspect for us. The symposium<br />

gives us the opportunity to get in touch with German<br />

companies that offer high quality software solutions<br />

and that are very well organized,” says Cai Minh Giac, vice<br />

director of Phuvinh Technology Mechanical Ltd. from Ho<br />

Chi Minh City.<br />

Among the ASEAN countries, Vietnam has become an<br />

attractive industrial location and an important trading hub<br />

with increasing industrial production. The country is expanding<br />

its domestic production in order to manufacture<br />

higher-quality products, reduce costs and at the same<br />

time protect itself from international supply bottlenecks.<br />

It needs machine tools to achieve this. With a market volume<br />

of € 805 million, Vietnam is the 15 th largest machine<br />

tool market in the world. Nearly all of its demands is met by<br />

imports. Laser machines are on top of the required machine<br />

groups, followed by presses and lathes. However, the machine<br />

groups which are needed are constantly expanding.<br />

“Vietnamese imports are dominated by machinery from<br />

China, Korea, Japan and Germany,” explains Marko Walde,<br />

chief representative of the German-Vietnamese Chamber<br />

of Foreign Trade (AHK Vietnam). “German goods have<br />

an excellent reputation in Vietnam and are highly valued.<br />

And there are great opportunities for German exporters as<br />

a result of the strong demand in Vietnam, the modernization<br />

of production and the EVFTA free trade agreement.<br />

More than ever Vietnamese entrepreneurs accepted<br />

the invitation to the symposium<br />

source: AHK Vietnam<br />

Machinery imports totaled nearly $ 46.3 billion in 2021, 24.3 %<br />

higher than in 2020. The most popular types of machinery and<br />

equipment imported in 2021 included medical equipment and<br />

tools, followed by batteries, electrical switchgear and wireless<br />

telecommunications equipment.”<br />

German exports to Vietnam increased from € 12.9 million in<br />

2021 to € 19.5 million in 2022. The country thus rose from 47 th<br />

to 41 st place among the most important customer markets for<br />

German manufacturers. The Vietnamese market will remain<br />

attractive in the medium term.<br />

5-axis machining centre<br />

F 6000<br />

Designed for Production - with the 5th axis<br />

in the tool for high-performance and flexible<br />

series production.<br />

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

Premiere @ EMO<br />

18–23 September <strong>2023</strong><br />

Hall 12 | Booth C68<br />

More information:<br />

www.heller.biz/en/emo<br />

no.3, August <strong>2023</strong><br />


news & facts<br />

LACH DIAMANT – 100 Years<br />

Tradition. Passion. Innovation<br />

part 6:<br />

The start of CBN hard turning<br />

Turning instead of grinding<br />

Company founder Jakob Lach, 1894-1984<br />

(photo taken in 1980)<br />

Dear readers, in the last article<br />

(compare part 5: https://tinyurl.com/<br />

lachdiamant5), you could read about the<br />

introduction and beginnings of polycrystalline<br />

diamonds (PCD) for the superior<br />

cutting of aluminium and other nonferrous<br />

metals and composite materials;<br />

this happened – from today’s perspective<br />

– exactly 50 years ago.<br />

Today, I am taking you back to the<br />

events of 1974.<br />

I will begin with an anniversary, for once a<br />

personal occasion. On September 13 th , 1974,<br />

my father was celebrating his 80 th birthday<br />

with all his employees in the great hall of the<br />

“Kurhaus Wilhelmsbad” in Hanau.<br />

Even at this age, Jakob Lach was still the<br />

guarantor of good purchases of natural<br />

diamonds from global markets, mainly from<br />

Belgium, and, back in those years, natural<br />

diamonds were still much needed for diamond<br />

dressing tools and for turning tools.<br />

From my study of balance sheets in my possession,<br />

I could see that the sales of LACH<br />

DIAMANT® had more than doubled between<br />

1969 and 1974.<br />

Jakob Lach celebrated his birthday on a<br />

big scale with all his employees in the Kurhaus<br />

Wilhelmsbad in Hanau, but preferred to<br />

celebrate with the smaller group of his<br />

diamond cutters in his backyard.<br />

24 no. 3, August <strong>2023</strong>

news & facts<br />

At this point in time, natural diamond tools<br />

were still the main sales and profit factor,<br />

followed closely by the massively emerging<br />

diamond and CBN Borazon® grinding wheels<br />

and polycrystalline diamond cutting tools under<br />

the name of dreborid® PCD.<br />

Back then, namely in 1972, my father took<br />

me on as a limited partner, and the sole proprietor<br />

company “Jakob Lach” became<br />

“Jakob Lach GmbH & Co. KG” – in short<br />

LACH DIAMANT®. The company expanded<br />

in size. The production of diamond and CBN<br />

grinding wheels had already taken on its own<br />

status, and was managed by Gerhard Iffland<br />

and Kurt Hemerka, and was located at the<br />

newly established factory 2 at Fasanerieweg in<br />

Hanau.<br />

The same applied to the expansively growing<br />

production of polycrystalline and natural<br />

diamond cutting tools at the main factory at<br />

Bruchköbeler Landstrasse 39-41 under Kurt<br />

Wagner (†), Gerhard Mai and technical engineer<br />

Günter Hobohm.<br />

Jakob Lach himself was ever-present as the<br />

much sought-after expert on natural diamonds.<br />

Advertising brochure for the Hanover spring tradeshow in 1975<br />

Back to 1974: as history tells us, the terracotta<br />

army of 7,000 life-sized figures was discovered<br />

in China; Hewlett Packard succeeded<br />

in making the HP65, the world’s first programmable<br />

pocket calculator; and the first<br />

VW Golf was launched on the market.<br />

Euphoria, ahead of time<br />

Back to LACH DIAMANT®: maybe, at<br />

least some of you will remember our slogan<br />

“Borazon® – Abrasive of a new Era” which was<br />

communicated in 1969, during our first presentation<br />

of a Borazon® CBN grinding wheel<br />

at the Hanover spring tradeshow. In part 5<br />

of this series you could already read about<br />

how my exuberant imagination played a trick<br />

on me. Due to my personal euphoria for the<br />

new abrasive Borazon® (Trademark General<br />

Electric), it was clear to me that GE’s announcement<br />

of a new abrasive could only be<br />

a Borazon®/CBN product. However, I was<br />

wrong. Instead of a cutting material made<br />

from CBN, much like Borazon®, GE surprised<br />

us in 1973 with the presentation of polycrystalline<br />

diamonds (PCD). Then we knew!<br />

A year later, in 1974, another surprise<br />

followed, and on top of that from an unexpected<br />

direction, that is to say, from Moscow.<br />

Via Hempel, at that time a company dealing<br />

with imports of silicon carbides, I was asked<br />

whether we had any interest in a synthetic<br />

Elbor CBN aggregate, sintered into a matrix<br />

product named “Elbor” for cutting metal. Apparently, they had become<br />

aware of LACH DIAMANT® because of our PCD activities. “Elbor, yes, of<br />

course,” if this should be the fulfilment of my wish for a “Borazon®” cutting<br />

material.<br />

no.3, August <strong>2023</strong><br />


news & facts<br />

Center Kurt Wagner (†), on the right<br />

Horst Lach, during the flight from<br />

Moscow to East Berlin<br />

I agreed to travel from East Berlin to Moscow.<br />

Product manager Kurt Wagner (†) and I landed<br />

in Moscow a few days before Christmas 1974.<br />

Ministers of the Soviet Food Department<br />

(apparently at that time responsible for the<br />

Russian diamond industry) welcomed us in a<br />

very friendly manner. A special highlight was<br />

an evening invitation to a “dacha”, far outside<br />

of the zone allowed for foreigners, as we<br />

were told with a wink. We had Vodka, and so<br />

many shots of it that my companion was feeling<br />

quite ill, despite his attempts to refuse it.<br />

According to the homepage of V-Bakul Institute for Superhard Materials, the<br />

facility was largely destroyed by the first missiles aimed at Kiev, shortly after the<br />

beginning of the war in Ukraine; shown here is a part of the institute’s premises<br />

Our “Elbor” business almost became a minor matter. The product was a<br />

pure pressed CBN body with a size of 0 8 x 6 mm. The delivery contract stipulated<br />

delivery exclusively via the company Hempel. At the end, we were invited<br />

to a “spontaneous” helicopter ride to Kiev in order to meet Professor<br />

Bakul from the “V-Bakul Institute for Superhard Materials”. For understandable<br />

reasons, we had to decline. It would have been interesting, that is for<br />

sure. Today, in <strong>2023</strong>, we could not make up for it; last year, the entire complex<br />

of the institute was destroyed by some of the first missiles on Kiev.<br />

Shopping adventures in Moscow<br />

Before our flight back, and thinking of the upcoming Christmas holiday, we<br />

went for a last shopping trip at Gum’s department store. We did not have<br />

much time. A very popular display of large Babuschkas (rag dolls) on the<br />

second floor caught our eyes. Each one of them like a “grandma with spectacles<br />

on her nose, and with a flowing big skirt.” “This might be something for<br />

our little ones.”<br />

This is how you can picture the doll<br />

purchased at Gum’s department store;<br />

45 cm large, meant for use as a coffee cosy<br />

(photo credits ebay)<br />

We were caught in the order process, which, at this point, was still unknown<br />

and confusing to us. We communicated the order quantity with<br />

“hands and feet,” calculated the total on a wooden slide rule. We paid with<br />

our last remaining roubles, and we then had purchased about seven of the<br />

voluptuously large Babuschkas. No explanations from me about the further<br />

course of events… (Only this much: the above-mentioned dolls turned out to<br />

be coffee cosies.)<br />

26 no. 3, August <strong>2023</strong>

news & facts<br />

At the Moscow airport lounge, we were already<br />

expected. “Unfortunately there would<br />

be a delay in our departure, the airport was<br />

blocked off. A big shot was expected: president<br />

of the state council, Willi Stoph.”<br />

Afterwards, during boarding into the tubeshaped<br />

Tupolev plane, our assistants prevented<br />

us from going into the normal coach area,<br />

and guided us towards the first-class seats.<br />

That was good (see photo, left side). Until the<br />

East German captain of Interflug asked us to<br />

stop photographing because we were now over<br />

Russian territory (no one suggested to reduce<br />

our intake of drinks …)<br />

Hours turn into minutes<br />

Back in Hanau, we started the new year of<br />

1975 with first preparations for the Hanover<br />

tradeshow in spring. What do we do with<br />

“Elbor”? Once again, chance came to our rescue,<br />

and, most significantly, via Borazon®:<br />

A “customer problem” occurred during the<br />

polishing of a metal-powder-coated cylinder.<br />

The customer found the grinding time with a<br />

CBN grinding wheel too long. “Well, we could<br />

try this compact CBN, this “Elbor” material.<br />

Thought, and done.<br />

Soldering, like with PCD, was unsuccessful<br />

without a solderable carbide carrier. Soldering<br />

in a vacuum was at that time no option,<br />

so the only alternative was to sinter the<br />

“Elbor” aggregate. Initially, the first attempt<br />

with a turning steel, made in such a way, was<br />

already successful. “This will be our tradeshow<br />

highlight; we will demonstrate it on a<br />

Weiler turning lathe.” And so, it happened<br />

at the Hanover spring tradeshow; the “new”<br />

product was successfully introduced under<br />

the name “dreborid®-G-AS“ for machining of<br />

metal-powder-coated turning parts. For the<br />

first time this resulted in minutes of turning<br />

time instead of hours of grinding time, and<br />

with almost polished surfaces. The first step<br />

toward better performance and efficiency during<br />

hard turning was made.<br />

Initially it was only a market niche for<br />

powder manufacturers who propagated the<br />

metal powder coating process – at that time<br />

especially Metco (today Oerlikon-Metco) and<br />

Castolin – for them, the dreborid®-G-AS turning<br />

tools were like a present.<br />

Their customers complained too much<br />

about high grinding times during the levelling<br />

of flame-sprayed turning parts, coated<br />

with alloys of nickel, chrome and tungsten<br />

carbide – no matter whether it was for repairs<br />

Hanover spring tradeshow in 1975 –<br />

first introduction of dreborid®-G CBN lathe tools for<br />

turning sprayed-on materials, HSS, cast and high-alloy hardened steel<br />

or wear protection. Turning instead of grinding immediately resulted in up<br />

to 90 % reductions in time. During this phase, Metco and Castolin provided<br />

repair kits (developed by us) to all their application technicians. The kits contained<br />

one dreborid®-G-AS turning tool and a specially designed dreborid®-<br />

G-Diamond grinding wheel.<br />

Due to CBN’s lower hardness, compared to PCD, it was possible to regrind<br />

cutting edges yourself, even with diamond grinding wheels.<br />

Encouraged by these first experiences, we let our search be guided for<br />

other possible applications by the positive experiences with the use of<br />

Borazon® CBN grinding wheels. In fact, both removal processes, grinding<br />

no. 3, August <strong>2023</strong><br />


news & facts<br />

and turning, work well with materials of 58<br />

and 62 HRC, for example high-alloy hardened<br />

steel. We realised that from now on, there<br />

would be an increasing “gap” between grinding<br />

with CBN and machining with polycrystalline<br />

CBN cutting materials, independently<br />

from continuous attempts of the manufacturers<br />

of cutting tools to break this tendency with<br />

newly-developed carbide and ceramic types.<br />

The turning of high-alloy hardened steel<br />

was at that time purely experimental, especially<br />

because our initial fear was gradually<br />

confirmed. The composite body with 0 8 mm,<br />

delivered as “Elbor”, could only be used up<br />

to approximately 35 % when mounted to the<br />

holder with our chosen fastening; beyond<br />

that, the body would break out. What the<br />

CBN body was lacking for a stable connection,<br />

was a solid solderable carbide base, as known<br />

from polycrystalline diamond (PCD).<br />

Possibly alerted by our success with<br />

dreborid®-G-AS, the manufacturer General<br />

Electric informed us at the end of 1975 that<br />

they could now also offer polycrystalline CBN<br />

blanks but now, with CBN tightly connected,<br />

and with a solderable carbide base.<br />

Gaining Speed<br />

LACH CBN tools for turning and milling<br />

of high-alloy hardened steel, and known under<br />

the name dreborid®-G, could now gain<br />

further momentum. Each day brought new<br />

results and more satisfied customers, and it<br />

became part of the 100-year history of LACH<br />

DIAMANT®.<br />

However, we developed even further. Without<br />

the new buildings, a new office building<br />

and factory on the premises of Bruchköbeler<br />

Landstr. 41, and the large, rented facility at<br />

Fasanerieweg, we would have by far met our<br />

capacity limits, even back then. In addition,<br />

the turbulent developments in the area of<br />

polycrystalline cutting tools and in the production<br />

of diamond and CBN grinding wheels<br />

took their course far too quickly. By dynamically<br />

tackling the new technologies for grinding<br />

hardened steel (initially only offered by<br />

General Electric in 1969), Borazon®/CBN<br />

abrasive grits, and in 1973 also polycrystalline<br />

diamonds, the LACH DIAMANT® company<br />

had become like a pioneer and was now a constant<br />

factor in the market.<br />

In 1974/75, cutting tools under the name<br />

dreborid®-G were added to the portfolio, adver -<br />

tising to turn “hours of grinding into minutes<br />

of turning”, especially for super-hard abrasive<br />

materials. This was actually unbelievable!<br />

Dreborid-G-AS,<br />

used during the machining of metal-powder-coated wear components;<br />

hours of grinding time “turned” to minutes of turning time<br />

“Now, we can take our time and build on this,” my father and I thought.<br />

But, as already mentioned, the future held further developments for LACH<br />

DIAMANT®, all determined by sudden chances, courage and determination<br />

when seizing new and suddenly available opportunities…<br />

Yours, Horst Lach<br />

PS: some articles of our 100-year anniversary are still to come; if you are<br />

interested, the first five parts of this article series, going all the way back to<br />

the founding of the company, can be found here:<br />

https://bit.ly/anniversary-series<br />

further information: www.lach-diamand.com<br />

28 no. 3, August <strong>2023</strong>

processes<br />

Burrless chamfering with world’s first V-shaped blade<br />

Nowadays, as the needs for environment friendly and value-added<br />

products increase, more parts are made lightweighted and highly functional.<br />

For this reason, increasing numbers of workpieces are lower in rigidity<br />

because of the complex shape, and difficult to cut because of enhanced<br />

strength. Therefore workpieces are increasingly more difficult to cut.<br />

Especially in medical and aircraft industries, additive (AM) is adopted to<br />

efficiently produce parts in complicated shapes.<br />

However, at mass production sites in the automobile industry, where<br />

monthly hundreds of thousands of vehicles are manufactured, use of 3D<br />

printers as replacement for metal molds is limited, because of costs and production<br />

speed reasons. Therefore the cutting process will remain essential in<br />

the future. When cutting the workpieces in mass production, increasingly<br />

difficulties can occur, opposing to small production, since in mass production<br />

stability is required.<br />

For example, when the rigidity of the workpiece is lowered, there may<br />

occur problems, such as vibrations, lowered surface roughness and change<br />

in size, affected by the change in machinability caused by a different lot,<br />

lowered tool sharpness by tool wear and changing cutting resistance. This<br />

uniformity in continuous machining can lower the process quality, leading<br />

to lowered workpiece quality.<br />

This not only applies to the size accuracy. When you think of the process<br />

of manufacturing a part throughout to the finish, it also affects deburring.<br />

Burrs formed in the cutting process can vary in size and shape because of the<br />

change in material and tool wear. There are<br />

different possibilities to remove burrs, which<br />

can cause instability in mass production.<br />

Production engineers are required to not<br />

only know the accurate size but also burr conditions,<br />

which is part of the product quality,<br />

and requires to take necessary measures to<br />

secure stability in mass production by equipment,<br />

jigs, tools and machining methods.<br />

Design specifications<br />

have an effect on<br />

the deburring process<br />

When a workpiece is cut, burrs will be formed<br />

only on the edges. Therefore it is important<br />

to know the requirements for the edges of<br />

a workpiece. To form “a sharp edge with all<br />

burrs removed”, cut the workpiece to form<br />

a sharp edge and remove all burrs in the deburring<br />

process. For “chamfering” and “round<br />

chamfering”, cutting and the removal of burrs<br />

takes place at the same time.<br />

When cutting the workpiece, secondary<br />

burrs can be formed. Although only slightly,<br />

these burrs formed by chamfering have to be<br />

removed.<br />

Aluminum component with semicircular contour on which the XEBEC<br />

Burrless Chamfering Cutter was tested. The flitter burr after pre-machining<br />

is clearly visible. Even the first test showed the full potential of the new<br />

chamfering cutter, because after the first pass there was no longer any<br />

burr to be seen (clearly visible in the close-up photos, right).<br />

The edge specification of “rounding range”<br />

is becoming popular. Rounding range means<br />

that the shape of the edge is not specified, and<br />

that it is possible to use a chamfering tool, or<br />

modify the edge shape in the deburring process<br />

after chamfering as long as it is within the<br />

range. Therefore, when the edge shape does<br />

not need to have a certain shape for a particular<br />

feature, such a specification allows various<br />

options for edge finish.<br />

no.3, August <strong>2023</strong><br />


processes<br />

The mode of action of the patented V-shaped cutting edge is decisive for the secondary burr-free end result. In principle, the<br />

process can be divided and illustrated in three stages: the outer area of the cutting edge shears off the top edge of the material and<br />

pushes the chip towards the center of the bevel. The inner part of the cutter is then used and pushes the chip upwards towards the<br />

center of the bevel. Finally, the chip is sheared off the workpiece at the center of the bevel and the tool leaves the point of contact<br />

with the workpiece. This procedure eliminates burr formation on the chamfered edge. Positioning accuracy is also improved<br />

by a flat tip that is resistant to rounding and chipping that would lead to measurement errors in tool length.<br />

Necessity of burrless chamfering<br />

Burrs are unwanted by-products formed by<br />

cutting tools in the process of shaping the<br />

parts. Ideally no burrs are formed in the cutting<br />

process. Most of the offered products are<br />

tools for the removal of burrs appearing on<br />

workpieces, filling the gap between ideal and<br />

reality.<br />

Since shaping the workpiece edges exactly<br />

is not possible, it is necessary to use a cutting<br />

tool for chamfering/round chamfering on the<br />

workpiece edges. By doing so again burrs will<br />

be formed on the chamfered edges. Therefore<br />

deburring is performed twice. The costs<br />

for performing edge finishing twice is not ignorable.<br />

Even if the process is automated, for<br />

example, to process 200,000 pieces per month! If it takes 5 seconds per piece<br />

to process, it takes 277 hours per month.<br />

Chamfering Features and Properties: chamfering is used to facilitate the<br />

assembly of parts and to prevent assembly problems that can occur due to<br />

overlapping part edges. In addition chamfering can prevent scratches and<br />

injuries during handling. What are the characteristics of roll chamfering?<br />

There are very few exact size requirements, although there are exceptions:<br />

for example, accuracy is unlikely to be affected by tool friction, but burrs<br />

formed during chamfering affect the rolls during chamfering.<br />

From this knowledge, XEBEC Technology was able to develop a burr-free<br />

Chamfering Cutter. The aim is to keep the burr size small; this results to an<br />

extension of the tool life, which is usually defined as being dependent from<br />

the burr size. It also eliminates the need for deburring after chamfering.<br />

If the current machining process includes deburring after chamfering, the<br />

deburring process can be eliminated, or the burr prevention effect can help<br />

to extend the tool life of the deburring tool. As a result, burrless chamfering<br />

can help to reduce idle time of machines, improving the productivity and<br />

reducing the costs.<br />

V-shaped blade mechanism<br />

Most Chamfering Cutters have straight blades. By using a cutter with a<br />

straight blade, poisson burrs which form orthogonally to the tool direction,<br />

can be formed on the upper and lower parts of the chamfered edge.<br />

Poisson burrs are formed because the workpiece material is pushed forward<br />

during cutting, and the material escapes orthogonally. The V-shaped blade<br />

developed by XEBEC is designed to make the plastic flow of the workpiece<br />

go toward the inside of the chamfering range, as to eliminate formations of<br />

poisson burr.<br />

A close-up of the patented cutting geometry<br />

with the V-shaped cutting edges. It took<br />

almost five years to develop this special shape,<br />

which offers clear advantages over straight<br />

cutting edges. Longer tool life, higher feed rates<br />

and no secondary burrs are guaranteed.<br />

If we now look at the test results with the V-shaped blade and the straight<br />

blade when chamfering workpieces made of different material, we can see<br />

that the V-shaped blade has a burr-preventing effect when chamfering different<br />

materials.<br />

For example, when deburring workpieces made of fibrous materials such<br />

as CFRP and woven Bakelite with the straight blade, the fibers remaining on<br />

the workpieces had to be removed manually. On the other hand, when the<br />

V-shaped blade was used to deburr the workpieces, no fibers were left on the<br />

edges and the surface layer was not removed.<br />

30 no.3, August <strong>2023</strong>

processes<br />

Another test took place on a quite complex stainless steel component. For experimental purposes, the burr formation was<br />

maximised during the preliminary work – but the burrless chamfering cutter also removed this hefty burr in one pass<br />

without leaving any residue and a uniform chamfer was applied.<br />

Preventing burr formation stabilizes<br />

mass production<br />

A test was conducted to determine the difference<br />

in tool life between the V-shaped cutter<br />

and the straight blade cutter by measuring<br />

the size of the burr. Both cutters were made of<br />

the same material and given the same coating.<br />

The machining parameters were as follows:<br />

workpiece material: stainless steel |<br />

speed: 6000min -1 | feed rate: 1200 mm/min<br />

Results and observations<br />

Tests indicate the burr size is correlated to the cutting distance, when using<br />

either the V-shaped blade or the straight blade cutters.<br />

Regarding the burrs on the upper edges, the difference is not significant<br />

at the beginning of cutting. But as the cutting distance advanced due to the<br />

blade wearing out, the burr size suddenly got bigger with the straight blade.<br />

Whereas with the V-shaped blade cutter the growth of burrs remained moderate.<br />

As a result there was a significant difference in burr size in the end.<br />

Regarding the burrs on the lower edges the difference in using different<br />

blades is significant, even from the beginning of cutting. Under the general<br />

standard of quality inspection, the tool life of the V-shaped blade is twice<br />

as long as that of the straight blade. From the results of several tests, it is<br />

verified that the V-shaped blade has the following effects<br />

■ prevents burr formation on workpieces made of various materials<br />

■ prevents the growth of burrs caused by the friction of the tool<br />

The quality of the workpiece is a target that can be achieved by fulfilling<br />

the requirements. However, in the cutting process, undesirable burrs are<br />

formed on the workpiece edges. Therefore, it is necessary to remove burrs<br />

after cutting to make the workpiece as close to as specified in the drawing. The<br />

appearance of each workpiece can vary when manually deburred. Even when<br />

the workpiece is deburred in an automated process, unwanted patterns or<br />

tool marks can emerge, depending on the used deburring tool.<br />

An overview of the different types of Burrless<br />

Chamfering Cutter. On the far left and lying,<br />

the type 06M with four cutting edges and<br />

high-temperature resistant AlTiCrN coating.<br />

Next to the right, type 06N, also with<br />

four cutting edges but without coating, but<br />

with extremely sharp cutting edges without<br />

rounding. Then the type 03M with stepped<br />

shank, three cutting edges and AlTiCrN<br />

coating and on the far right the type 03N<br />

with stepped shank, three cutting edges<br />

but without coating.<br />

For the customer one of the requirements is the appearance of the workpiece.<br />

But it is not necessary to provide products that are overly excellent in<br />

appearance. However, the products vague in appearance can be regarded as<br />

uncertain in accuracy even when the accuracy is up to the standard. Burrs<br />

are formed on the edges of the workpieces. That means, securing the edge<br />

quality, which is an important matter in appearance inspection, is an important<br />

final touch to finish the product.<br />

XEBEC Technology is a specialist deburring tool manufacturer based in<br />

Japan. XEBEC pioneered the use of ceramic fiber brushes in deburring and<br />

has been helping factories and machining shops automate their deburring<br />

processes since 2002.<br />

further information: www.xebec-tech.com | www.kempf-tools.com<br />

no.3, August <strong>2023</strong><br />


processes<br />

Lightweight damper system for use in<br />

lightweight structures<br />

written by<br />

Thomas Götz and Ralf Müllner,<br />

Fraunhofer Institute for Manufacturing Engineering and Automation IPA<br />

Lightweight structures can offer productivity<br />

advantages, especially in highly dynamic applications<br />

such as machining technology, but they are significantly<br />

more susceptible to vibrations than solid structures.<br />

The research project “LeDALe” addresses this<br />

challenge and aims to develop weight-reduced damper<br />

systems for integration into lightweight structures,<br />

which will be tested on the applications chuck and cutting<br />

tool.<br />

In the context of modern, highly automated series production,<br />

machine and plant manufacturers are increasingly confronted<br />

with a trend towards shorter cycle times, greater<br />

diversity of variants and decreasing batch sizes. Meeting<br />

these demands requires the development of highly productive<br />

and flexible machine and plant concepts, which at the same<br />

time must be offered to the customer at a minimum price.<br />

Often these objectives go hand in hand with the need for a<br />

highly dynamic working speed of the machines, which in<br />

turn is significantly related to the weight of moving machine<br />

parts. A mass reduction of these machine parts leads to a<br />

more favourable machine dynamics and thus to an increase<br />

in productivity. Here, the use of modern lightweight materials<br />

and principles can make a decisive contribution and<br />

achieve concrete technological added value at simultaneously<br />

minimized costs. [1]<br />

However, machine structures in lightweight construction<br />

are often significantly more susceptible to vibrations com-<br />

pared to conventional solid construction due to their low<br />

system damping. Particularly in highly dynamic applications<br />

such as metal-cutting machines, these vibrations have<br />

a disruptive effect on the work process during operation. The<br />

results are high noise emissions, poor machining quality or,<br />

in extreme cases, even damage to the machine and its components<br />

due to high vibration amplitudes.<br />

The research project “LeDALe – Lightweight damper system<br />

for use in lightweight structures” addresses this challenge and<br />

aims at the development of weight-reduced damper systems<br />

for integration into lightweight constructions which are to be<br />

put into practice and validated in two common applications<br />

in the area of machinery and plant engineering, the chuck<br />

and cutting tool.<br />

Vibration phenomena in the machining process<br />

In the machining process, dynamic disturbances can occur<br />

in the form of different vibration phenomena (table 1). Basically,<br />

a distinction must be made between self-excited and<br />

[2, 3]<br />

externally excited vibrations.<br />

Externally excited vibrations are due to an external excitation<br />

force, which can occur either impulsively or periodically.<br />

The impulse excitation is caused, for example, by a fast axis<br />

movement or by cutting into material inhomogeneities. The<br />

externally excited vibration after a single excitation is characterised<br />

by the fact that the machine system with its natural<br />

externally excited vibrations<br />

self-excited<br />

vibrations<br />

impulse excitation periodic excitation dynamic instability<br />

cause of<br />

vibration<br />

• cutting into material<br />

inhomogeneity<br />

• fast axis movement<br />

• …<br />

• cutting edge entry during<br />

interrupted cut<br />

• imbalances<br />

• …<br />

• regenerative effect<br />

• noise floor of the<br />

cutting forces<br />

• …<br />

system<br />

response<br />

system response with<br />

natural frequency<br />

system response with<br />

excitation frequency<br />

system response in the range<br />

of a natural frequency<br />

table 1<br />

Types of vibration and their causes according to [2]<br />

32 no. 3, August <strong>2023</strong>

processes<br />

frequency is set into vibrations, which decay exponentially<br />

[2, 3]<br />

due to the system damping.<br />

With periodic external excitation, however, the vibrational<br />

system is excited at the excitation frequency. In this context,<br />

examples include cutting engagement impacts during<br />

the milling process in which the machine structure<br />

connected via the milling tool resonates with the periodic<br />

excitation frequency. The closer this excitation frequency is<br />

to the machine’s natural frequency, the higher the amplitudes<br />

of the externally excited vibrations. The amplitudes reach<br />

their maximum when the excitation frequency coincides<br />

with the natural frequency of the machine, which is called<br />

[2, 3]<br />

resonance.<br />

Approaches<br />

In contrast, no external perturbing forces act on the machine<br />

system during the self-excited vibration. Instead, the<br />

vibrations result from the interaction between the cutting<br />

process and the connected machine structure. If, for example,<br />

the machine system is subjected to externally excited<br />

vibrations due to cutting edge entry, the vibration leaves a<br />

ripple on the workpiece surface. This ripple is particularly<br />

pronounced at vibration amplitudes in the resonance frequency<br />

of the machine due to its greater compliance for this<br />

frequency [3] . The chip thickness changes caused by the ripple<br />

in turn induce an increased vibration excitation of the machine<br />

in the natural frequency during chip removal by the<br />

subsequent tool cutting edge, which is referred to as the regenerative<br />

effect (figure 1). The self-excited vibration is thus<br />

a consequence of the surface ripple generated by the external<br />

[2, 3]<br />

excitation, which leads to greater process instability.<br />

to reduce vibrations<br />

Various methods are available to reduce vibration phenomena<br />

in the machining process.<br />

This includes, among other things, the decoupling of the<br />

excitation by the use of elastic intermediate components, the<br />

so-called insulating elements. However, decoupling close to<br />

the excitation in the force flow of the machine structure, e.g.<br />

at the tool holder or workpiece clamping device, is usually<br />

associated with high resilience and therefore can only be<br />

[2, 5]<br />

implemented with great restrictions.<br />

Another approach aims at changing the excitation frequency<br />

by selecting suitable cutting parameters so that it is<br />

no longer in the range of a dominant resonance frequency of<br />

the machine structure. However, this measure requires a certain<br />

amount of experience on the part of the operating personnel<br />

and often affects productivity, as it is usually necessary<br />

to deviate from the optimum process parameters. Thus,<br />

either the process time is extended when the parameters are<br />

reduced or the tool life is shortened when the parameters are<br />

[5, 6]<br />

increased.<br />

The withdrawal of the vibration energy can also be achieved<br />

via the principle of material damping. In this case, vibration<br />

energy can be converted into heat through the use of viscoelastic<br />

materials. Physical causes of this energy dissipation<br />

are, for example, sliding processes or microplastic deformations<br />

in the damping material. Currently, there are concepts<br />

of toolholders with integrated viscous dampers which have<br />

up to 90 % less dynamic compliance compared to undamped<br />

figure 1<br />

Regenerative self-excited vibrations<br />

using the example of grooving [4]<br />

first impulsive excitation<br />

cutting a ripple on the<br />

workpiece<br />

incision in the waviness<br />

after a workpiece rotation<br />

upswing of the process<br />

(chatter vibrations)<br />

no. 3, August <strong>2023</strong><br />


processes<br />

figure 2<br />

left:<br />

Spring-mass system of vibration absorber and auxiliary mass damper [7]<br />

right:<br />

Cutting tool system with auxiliary mass damper [8]<br />

toolholders. However, these concepts require an increased<br />

static compliance of the tool clamping to allow higher deformations<br />

of the viscous dampers. The increased static compliance<br />

of the tool holder, however, results in a higher tool displacement<br />

and thus leads to dimensional and shape errors. [6]<br />

Principle of vibration absorber<br />

Another important method of damping vibrations is the<br />

principle of vibration absorber (figure 2, left), whereby the<br />

vibration is compensated for by means of additional masses.<br />

If a harmonic excitation with a certain frequency acts on<br />

a vibrating system, the system will vibrate with the same<br />

frequency. If an absorber mass is coupled to this system by<br />

means of a spring, the absorber executes oscillating movements<br />

in the opposite direction to the excitation, thereby<br />

withdrawing oscillation energy from the main system for its<br />

own oscillating movement. Provided, the absorber’s natural<br />

frequency is optimally tuned to the excitation frequency<br />

to be eliminated, the vibrations of the main system mass<br />

can be completely stopped, whereby two new pronounced<br />

resonance points are formed. However, this behaviour only<br />

occurs with ideal, i.e. pure spring coupling. Under real conditions,<br />

the spring-mass oscillator also has a damping component<br />

in the coupling and is called an auxiliary mass damper<br />

(figure 2, left). Although the vibration to be eliminated is not<br />

completely suppressed here, the new resonance points do not<br />

form as strongly.<br />

Contact<br />

Auxiliary mass dampers are already being used successfully<br />

by some cutting tool manufacturers for damping overlong<br />

cutting tools (figure 2, right) as well as long, slim extensions<br />

with large length-to-diameter<br />

[2, 5, 7, 8]<br />

ratios.<br />

surface damping and<br />

hydraulic expansion chuck<br />

An alternative to vibration absorbers is the contact surface<br />

damping, in which the vibration energy is converted into heat<br />

via a friction process (figure 3, left). In a first implementation<br />

of this principle on tool holders for long projecting rotating<br />

cutting tools, friction bars are used to reduce vibrations (figure<br />

3, right). A deformation of the basic structure leads to a<br />

relative movement between the prestressed friction bars and<br />

[6, 9]<br />

the basic structure, whereby a friction work is realised.<br />

Another application example in the field of contact surface<br />

damping is the hydraulic expansion chuck. In this system,<br />

by turning a clamping screw in the pressure chamber of the<br />

hydraulic system, a pressure is generated which leads to the<br />

elastic deformation of the expansion sleeve. The cutting tool<br />

located in the clamping sleeve is thereby clamped forcefully<br />

(clamping connection). In the process, the relative movements<br />

in the contact surfaces between cutting tool and<br />

clamp ing sleeve lead to friction, which contributes to vibration<br />

damping of the system. [10]<br />

All previously realized designs for contact surface damping<br />

are exclusively available in solid designs in order to support<br />

the normal force (clamping force) required to build up<br />

the frictional force.<br />

Summary and outlook<br />

With regard to the state of the art, it can be concluded that<br />

many successful approaches to increase damping in cutting<br />

tools and clamping devices already exist, which, however,<br />

require a high degree of competence in process control or are<br />

not designed for lightweight construction.<br />

34 no.3, August <strong>2023</strong>

processes<br />

F = applied force<br />

F R = frictional force<br />

F N = normal force<br />

figure 3<br />

left: Principle of friction<br />

right: Tool holder based on friction strip dampers [9]<br />

For the development of low-mass damper systems, the<br />

principle of the friction damper appears to be principally<br />

well suited. In order to achieve the highest possible degree<br />

of lightweight construction, this damping approach is to be<br />

realised within the framework of “LeDALe” using a combination<br />

of various lightweight construction principles and manufacturing<br />

technologies. These include lightweight design,<br />

which aims to minimise weight by optimising shape and topology,<br />

whereby a constant stiffness of the damper structure<br />

is achieved with low material input. Another option is lightweight<br />

manufacturing, in which weight-saving potentials are<br />

realised through manufacturing and production processes,<br />

such as additive manufacturing methods. The third approach<br />

is lightweight material construction, which enables weight<br />

reduction through the use of lightweight materials such as<br />

fiber composites.<br />

Acknowledgements<br />

The LeDALe research project is funded by the Baden-<br />

Württemberg Ministry of Economics, Labour and Tourism<br />

(WM BW) as part of the “Invest BW” funding programme<br />

and is supervised by the VDI/VDE-IT project management<br />

organisation. The authors would like to thank the WM BW<br />

for the funding granted. In addition, the authors would<br />

like to thank the project management organisation and all<br />

project staff involved for their support.<br />

Literature<br />

[1]<br />

Hansmersmann, A.; Birenbaum, C.; Burkhardt, J.;<br />

Schneider, M.; Stroka, M. (2016)<br />

Leichtbau im Maschinen-, Anlagen und Gerätebau:<br />

Herausforderungen - Potenziale - Mehrwerte - Beispiele.<br />

Handbuch für den praktischen Gebrauch.<br />

Internet: https://www.ipa.fraunhofer.de/content/dam/<br />

ipa/de/documents/Kompetenzen/Leichtbautechnologien/<br />

IPA_Leichtbaustudie_Leichtbau_im_Maschinenbau.pdf<br />

[2]<br />

Baur, M. (2013)<br />

Aktives Dämpfungssystem zur Ratterunterdrückung<br />

an spanenden Werkzeugmaschinen.<br />

Entwurf und experimentelle Validierung<br />

dissertation, Technische Universität München<br />

[3]<br />

Weck, M.; Brecher, C. (2006)<br />

Werkzeugmaschinen 5. Messtechnische Untersuchung<br />

und Beurteilung, dynamische Stabilität<br />

Berlin<br />

[4]<br />

Brecher, C.; Kiesewetter, C.; Kampka, M.; Epple A. (2016)<br />

Prozess-Maschine-Interaktion beim Verzahnungshonen<br />

in: Zeitschrift für wirtschaftlichen Fabrikbetrieb,<br />

volume 111, n° 11, pp. 723 - 726<br />

[5]<br />

Baron, J. (2000)<br />

Untersuchungen zur Auslegung und zum<br />

Betriebsverhalten eines fliehkraftgesteuerten<br />

frequenzvariablen Drehschwingungstilgers<br />

dissertation, university of Hanover<br />

6]<br />

Teige, C.<br />

Entwicklung gedämpfter Werkzeugaufnahmen für<br />

lang auskragende rotierende Werkzeuge<br />

[7]<br />

Tönshoff, K. (1995)<br />

Werkzeugmaschinen<br />

Grundlagen. Berlin<br />

[8]<br />

aufgerufen am 08.12.2021<br />

Schwingungstilger verbessert Qualität<br />

Internet: https://industrieanzeiger.industrie.de/technik/<br />

produkte/schwingungstilger-verbessert-qualitaet/<br />

[9]<br />

aufgerufen am 08.12.2021<br />

Entwicklung gedämpfter Werkzeugaufnahmen für<br />

lang auskragende, rotierende Werkzeuge<br />

Internet: https://www.ifw.uni-hannover.de/en/forschung/<br />

beendete-projekte/research-projects/projects/<br />

development-of-damped-tool-holders-for-longcantilever-rotating-tools<br />

[10]<br />

Fleischer, J.; Schulze, V.; Zanger, F.; Leberle, U.;<br />

Boev, N.; Spohrer, A. (2014)<br />

Spanntechnikvergleich bei der Hochleistungszerspanung.<br />

Hydrodehnspannfutter verbessern Werkzeugstandzeit,<br />

Qualität und Produktivität<br />

in: VDI-Z, August<br />

further information: www.ipa.fraunhofer.de<br />

no.3, August <strong>2023</strong><br />


processes<br />

Digital transformation in tooth machining<br />

Time-consuming and costly operations were the<br />

trigger for KAPP NILES to introduce digitalisation<br />

into its machining and support processes.<br />

Particular emphasis was placed on local integration,<br />

but at the same time on the possibility of interfaces in<br />

customer systems. This ensures easy installation and<br />

integration into the existing Industry 4.0 landscape.<br />

With the innovative software platform KN assist the<br />

company has succeeded in finding a practical solution.<br />

Take the set-up process to a new level<br />

Set-up processes are time-consuming and involve the risk of<br />

errors. Since tooling is often used in a multilayered manner,<br />

tracking of the machined workpieces or the clamping cycles<br />

is difficult.<br />

The Kapp Niles Tool Management with guided changeover<br />

sequences at the plant guides the employee step by step<br />

through the set-up process. Within the sequences, the query<br />

for identification takes place. The machine recognises whether<br />

the component is correct for the grinding project, so that the<br />

geometric and process-relevant information is transmitted<br />

to the control system. The KN extender displays all relevant<br />

data of the stored components in a local database outside the<br />

machine (see figure 1).<br />

The use and quality of tooling can be better planned via<br />

stored data, such as clamping and dressing cycles.<br />

figure 1<br />

KN extender manages component inventory<br />

36 no.3, August <strong>2023</strong>

processes<br />

figure 2<br />

Dashboard views<br />

Transparency in production<br />

Together with its customers, Kapp Niles has sought a way to<br />

transparently present the Overall Equipment Effectiveness<br />

(OEE) key figures on the machine and on mobile terminals.<br />

The aim is to visualise the relevant KPIs (Key Performance<br />

Indicators) clearly and easily.<br />

With the Kapp Niles Production Monitoring System designed<br />

in this way, all connected machines can be displayed<br />

in a dashboard. Two views can be selected (see figure 2).<br />

The machine overview shows the status of a machine. The<br />

individual machine view displays monitored status values,<br />

OEE key figures, relevant production data and the number<br />

of workpieces processed. The job history gives an overview<br />

of the most used grinding projects. The tooling dashboard<br />

is used in conjunction with the tool management system to<br />

visualise information about the tooling currently in use.<br />

The system also provides an overview of all pending service<br />

requests. New inquiries can also be triggered directly.<br />

André Wetz, product manager at Kapp Niles, describes<br />

further advantages of the Production Monitoring System.<br />

“OEE key figures become easy to access and visualise. The<br />

optimized presentation of the KPIs and the most frequently<br />

used grinding projects specifically show potential in the<br />

production process and environment. The device-independent<br />

access to all relevant production data enables a transparent<br />

display at any time and from anywhere. Reaction times<br />

can thereby be minimized. Optimized communication leads<br />

to faster problem resolution and thus to shorter machine<br />

downtimes.”<br />

Real-time monitoring of the machining process<br />

In order to meet the ever increasing quality requirements<br />

on the component and a high productivity, Kapp Niles has<br />

been looking for a solution for monitoring the grinding and<br />

dressing process. Here too, the company was in close contact<br />

with its customers in order to detect and avoid abnormalities<br />

already in the process. This avoids an expensive 100 % test<br />

afterwards.<br />

The Monitoring System analyses the grinding and dressing<br />

process. The tool state is monitored and an evaluation of ripples<br />

or orders on the component is carried out. Based on the<br />

analysed data, the machining process is determined and visualized<br />

at the HMI. Through adjustable limits, messages indicating<br />

deviations are issued at an early stage. An interface<br />

offers the possibility of providing data via a partial tracing to<br />

each manufactured workpiece. Data outside the machine can<br />

also be analysed in detail via export functions (see figure 3).<br />

Andreas Paatz, head of division service and tools at Kapp<br />

Niles, explains: “This system ensures a comprehensive examination<br />

of relevant features during the grinding and dressing<br />

process. As a result, errors or trends can be detected at an early<br />

stage and scrap and reworking percentage can be reduced. By<br />

monitoring the machining process, conclusions can also be<br />

drawn about the condition of the machine. A further advantage<br />

is that a removal of noisy workpieces after the machining<br />

process is made possible. By means of partial tracing, it is<br />

possible to detect critical workpieces also retroactively. Since<br />

the number of workpieces to be subsequently measured can<br />

be reduced, time and cost savings are achieved.”<br />

figure 3<br />

Export functions facilitate the analysis of machine data<br />

no.3, August <strong>2023</strong><br />


processes<br />

figure 4<br />

Powerful IPC is used for monitoring<br />

From prevention to prediction<br />

If an unplanned machine shutdown occurs it can have a<br />

large impact on various factors, such as productivity and on<br />

the adherence to deadlines, depending on the cause, and ultimately<br />

entail additional costs. The Condition Monitoring<br />

System monitors the wear condition of the linear and rotary<br />

axes of the processing machine. By means of specific reference<br />

runs, the condition is recorded during operation of the<br />

machine. The degree of wear of the axes is visually shown<br />

on the HMI of the machine. In addition to a forecast of the<br />

service life, pre-set limits are used to output trends on the<br />

machine. Interfaces for the transmission of relevant data to<br />

further customer-specific production systems are available.<br />

Furthermore the data can be supplied to each manufactured<br />

workpiece via a partial tracing. In analogy to the process<br />

monitoring system, the machine is equipped with additional<br />

sensors and a powerful IPC for evaluating the recorded data<br />

for monitoring the axes (see figure 4).<br />

Andreas Paatz: “The aim is to significantly reduce unplanned<br />

machine downtimes. This allows better planning of maintenance<br />

intervals and prevents unnecessary or premature<br />

replacement of machine components. This is due to the fact<br />

that fewer wear parts have to be kept in stock and can be ordered<br />

on a condition-based basis. The trend in modern production<br />

plants is towards condition-oriented maintenance<br />

and repair. Kapp Niles offers a powerful product here.”<br />

Make maintenance transparent<br />

Unforeseen maintenance work makes life difficult. Unpredictable<br />

production downtime can lead to reduced productivity<br />

and increased costs. If maintenance is necessary, missing<br />

information leads to additional expenditure.<br />

The Maintenance Manager displays all maintenance plans<br />

and instructions in digital form. The database provides complete<br />

maintenance management with triggers, consumables,<br />

time expenditures, responsibilities and priorities. This enables<br />

usage-based maintenance. A traffic light function indicates<br />

when maintenance is due. All activities carried out are<br />

stored in the asset archive.<br />

This archive (see figure 5) is used to support the planning of<br />

maintenance processes.<br />

figure 5<br />

Planning tool for maintenance processes<br />

further information: www.kapp-niles.com<br />

38 no.3, August <strong>2023</strong>

processes<br />

Next generation CNC control<br />

The new CNC control by Okuma: the OSP-P500 raises production<br />

to the next level. Customers of the worldwide known manufacturer of<br />

CNC machine tools will benefit from the highest productivity and precision<br />

with special user-friendliness and energy efficiency. The smart<br />

machine control also includes special safety features to protect against<br />

cyber attacks.<br />

An increasing shortage of<br />

skilled workers, growing requirements<br />

for climate-neutral<br />

production and ever more<br />

flexible, multi-variant production<br />

programmes are causing<br />

a sharp rise in the demand for<br />

automated, energy-saving production<br />

processes. 60 years after<br />

the first launch of OSP control,<br />

Okuma is announcing a<br />

revolutionary innovation as the<br />

answer to current and future<br />

challenges.<br />

5th Leading Trade<br />

Fair for Deburring<br />

Technologies and<br />

Precision Surfaces<br />

10 – 12 October <strong>2023</strong><br />

Trade Fair Center<br />

Karlsruhe, Germany<br />

Efficient machining by everyone<br />

The new OSP-P500 control is equipped with the “Digital Twin” to speed up the<br />

production processes and reduce preparation times. It facilitates high-precision<br />

simulations of the machining processes: with “Digital Twin on Machine” this<br />

simulation takes place on the machine itself, so that machining can be started<br />

immediately afterwards. Simulation can also be done with “Digital Twin on<br />

PC” on a computer to prevent downtimes, allowing the machine to be used for<br />

other machining processes. Even inexperienced users benefit from all the advantages<br />

of the CNC control thanks to the exceptionally user-friendly interface.<br />

The “Smart OSP Operation” function simplifies handling and provides automatic<br />

guidance through all the necessary steps, meaning that people without<br />

any prior experience can learn how to machine a workpiece in a single day.<br />

The OSP-P500 is also ideally equipped for high-speed machining with high<br />

surface quality: thanks to “Smart Control”, it has twice the computing power<br />

of conventional machine controls. This significantly shortens reaction times so<br />

that the cycle times can be reduced by up to 15 %.<br />

Smart technology for greater energy efficiency<br />

Thanks to the integrated “Eco Suite Plus”, the new OSP-P500 meets all customer<br />

requirements of reducing the power consumption. The smart features record<br />

and analyses every operating status and CO₂ emissions, switch to energy-saving<br />

idling if required and automatically adjust peripherals, such as the chip conveyor<br />

or suction. In future Okuma will gradually launch a range of new Green<br />

Smart Machines. These intelligent machine tools are particularly designed for<br />

the reduction of CO₂ emissions with reduced energy consumption, while still<br />

ensuring the highest quality. The OSP-P500 is also part of the package.<br />

Knowledge<br />

Transfer<br />

& Solutions<br />

to produce components<br />

burr-free, precise and<br />

clean.<br />

New machine design for 5-axis machining centers and<br />

multitasking machines<br />

The 5-axis machining centers of the MU-V series and the multitasking machines<br />

of the MULTUS series will be equipped with the new machine control. The<br />

first machines with the new control and design will be delivered to customers<br />

in Europe at the end of <strong>2023</strong>.<br />

further information: www.okuma.eu<br />

© gonin | Fotolia.com<br />

deburring-expo.com<br />

no.3, August <strong>2023</strong> 39<br />

23-0025707 © w-id.de

machining center<br />

From watchmaker to precision manufacturer<br />

Opening new industries with a<br />

Kern Micro HD around the globe<br />

High precision manufacturing is the basis of every<br />

successful watchmaker. So why not use this knowledge<br />

for other industries? That’s what Nicholas Hacko<br />

thought. After founding “Nicholas Hacko Watchmaker”<br />

(NHW) in Sydney in 2011, he launched another company,<br />

NH Micro, in 2020. Here he works for many parallel<br />

precision industries – from medical technology to<br />

aerospace. Investments in the best five-axis milling<br />

technology – most recently in a Kern Micro HD – were<br />

decisive for his success.<br />

Nicholas and Josh Hacko are thrilled about their<br />

Kern Micro HD: “With the experience we have gained so far,<br />

we believe that this manufacturing center will pay for itself<br />

in less than five years, despite the high investment costs”<br />

Watchmaking and high-precision engineering are in the<br />

Hacko’s blood. When Nicholas Hacko emigrated from Europe<br />

to Australia in 1992, he was already working in the industry<br />

as a third-generation watchmaker. Since his son Josh was also<br />

learning the profession, he decided to start his own brand in<br />

2011 – NHW. The focus of NHW was to become an independent<br />

watchmaker in Australia, manufacturing high quality<br />

timepieces.<br />

Being aware that the highest quality requires the highest<br />

precision – and that this cannot be achieved without the best<br />

manufacturing technology – the small company invested in a<br />

used Kern Pyramid Nano five-axis machining center in 2017.<br />

Nicholas Hacko remembers: “It was a big investment for us.<br />

But it paid off extremely quickly. The machine reliably mills<br />

tiny parts like gears, bridges, mainplates, levers and other<br />

small parts with the highest level of accuracy, with very high<br />

efficiency.”<br />

The parts from NH Micro require manufacturing accuracies<br />

in the micrometer range and surfaces up to Ra ≤15 nm<br />

Internal watch production grew quickly and within 5 years<br />

NHW had released 5 models. This rapid growth begged the<br />

question: which other industries – beside the watchmaking<br />

industry – require unique parts manufactured with such high<br />

precision? Nicholas and Josh Hacko concluded that medical<br />

technology and aerospace companies, for example, would<br />

have great demands as growing markets. So it would be obvious<br />

to use existing knowledge and capacities and expand the<br />

field. Could, should, would. It was necessary to overcome the<br />

subjunctive and act.<br />

40 no. 3, August <strong>2023</strong>

machining center<br />

Rocket start with his job shop<br />

That’s exactly what the Hacko’s did for the first time at the<br />

end of 2018. “Our first non-watchmaking-industry part was<br />

for a Formula 1 racing team,” says Nicholas Hacko. “We were<br />

commissioned to produce sample parts. These were never<br />

used in serial production, but our client was satisfied and that<br />

was an eye-opener for us. We suddenly saw the enormous<br />

field of precision parts applications.”<br />

Orders from medical technology, mold-making and scientific<br />

instrumentation companies followed a short time later,<br />

and the business picked up speed. The watchmaker founded<br />

a second company called NH Micro in 2020. News of the<br />

high quality of Hacko precision parts spread quickly, causing<br />

sales to double from 2020 to 2021, even despite the Covid<br />

crisis. Accordingly the capacities of the Kern Pyramid Nano<br />

soon reached its limits. Nicholas Hacko asked his Kern advisor,<br />

Udo Reinwald, Kern Asia pacific director at the beginning<br />

of 2021 which solution he would recommend. With the<br />

rapid development and potential future of the two NH operations<br />

in mind, he suggested the world’s best five-axis machine<br />

for high-precision machining, the Kern Micro HD.<br />

Investing in the world’s best five-axis machine<br />

for high precision<br />

Nicholas Hacko was just as enthusiastic about this machining<br />

center as his son Josh. They recognized the potential and<br />

made a rather conservative ROI calculation. Josh Hacko explains:<br />

“It was a big investment for our small company with<br />

nine employees. However, seeing the potential that would be<br />

enabled with the new machining center, it should have paid<br />

for itself in around five years, our decision was quickly made,<br />

and we ordered the Kern Micro HD.”<br />

The machine was put into operation in March 2022. With<br />

full order books the Kern Micro HD now runs every day –<br />

without any problems. And their range of customers keeps<br />

growing. To name just a few examples: in addition to prototypes<br />

and small series’ of up to 500 pieces for medical technology,<br />

orders for opto-mechanical and microfluidic components<br />

are increasing, as well as for rocket propulsion nozzles,<br />

fiber optic connectors and dosing pump components.<br />

“There hasn’t been a part for which our Micro HD hasn't<br />

achieved the required accuracy,” says Nicholas Hacko happily,<br />

explaining the main requirements placed on his operation:<br />

“For our internal watch production, manufacturing accuracies<br />

of around five micrometers is quite common. But every<br />

now and then there are parts where bore positions and diameters<br />

with tolerances down to +/- 2 µm must be maintained.”<br />

This is no problem for the Kern Micro HD. If required, it also<br />

achieves precision of less than 1 µm in serial production.<br />

When it comes to surface quality, NHW and NH Micro<br />

also have very high standards. When processing different<br />

steels you need Ra values of ≤ 20 nm and, in some cases,<br />

Ra ≤ 15 nm for non-ferrous materials. Hacko says: “We achieve<br />

this reliably. However, I believe that even better values would<br />

be possible if required.” He is right, as Reinwald confirms:<br />

“With the Micro HD we can also achieve Ra values in the<br />

single-digit nanometer range.<br />

The Kern Micro HD is easy to operate and has extremely fast<br />

linear motors, resulting in very high processing speeds<br />

NH Micro, Sydney (Australia), …<br />

…was founded in 2020 by Nicholas Hacko. He started<br />

his own watchmaking company in 2011 (NHW), which<br />

has been producing up to 80 % of its watch components<br />

in-house since 2016. In 2018 Hacko began to work as a<br />

contract manufacturer, supplying precision parts to<br />

companies in other industries. Today the two small<br />

companies NHW and NH Micro employ nine people.<br />

no. 3, August <strong>2023</strong><br />


machining center<br />

Shown here is an internal automation package within the tool changing cabinet;<br />

up to 210 slots are available in the tool changer of the Kern Micro HD, enabling NH Micro<br />

to manufacture a wide range of different precision parts without having to change tools<br />

There is almost no temperature influence<br />

There are a few technological highlights, unique even for a<br />

precision machining center, that are decisive for accuracy.<br />

The Micro HD used by NH Micro has a sophisticated temperature<br />

management system that is unique to the market.<br />

With this special solution, the Kern Micro HD remains within<br />

a temperature range of +/- 50 mK even under extreme<br />

conditions. This is crucial because – according to recent research<br />

– temperature influences are responsible for around<br />

70 % of all accuracy errors in the high-precision area.<br />

Another advantage is in the large-scale and actively temperature-controlled<br />

linear motors. Compared to ball screw<br />

drives, they bring clear advantages in terms of dynamics<br />

and control accuracy and achieve rapid traverse speeds of<br />

60 m/min. Nicholas Hacko says: “This keeps our non-productive<br />

times very low. We are working much more efficiently<br />

than would be possible with other machines.”<br />

The owners of NH Micro – Nicholas and Josh Hacko – have<br />

precision in their blood, but they also regularly prove this<br />

with high-quality measurement technology<br />

The many technical refinements of the Kern Micro HD<br />

and their high quality, together with their ever-growing<br />

order book, make the Hacko’s optimistic for the future. The<br />

two companies are growing steadily, so that after 2021 their<br />

sales doubled again in 2022 – despite the difficult global<br />

situation. In addition to the Australian market orders from<br />

Europe and the USA are now also increasing. Accordingly<br />

Nicholas Hacko is even more relaxed about his latest investment<br />

today: “Based on the experience we have gained, I believe<br />

that it will take us less than five years for the Kern Micro<br />

HD to pay for itself.”<br />

further information: www.kern-microtechnik.com<br />

42 no. 3, August <strong>2023</strong>

A partnership for an automated future<br />

components<br />

At automatica <strong>2023</strong> (Munich) SCHUNK exhibited<br />

smart new developments that enable handling tasks to<br />

be solved transparently, flexibly and reliably.<br />

Making its customers’ processes understandable, simple and<br />

efficient is the declared goal of automation specialist SCHUNK.<br />

Data transparency plays an important role here. It enables reliable<br />

processes and provides the basis for resource-efficient<br />

planning, zero-defect production and energy efficiency. The<br />

digitalization of components and processes go hand-in-hand<br />

with sustainable manufacturing. It was shown how digital solutions<br />

lead to greater efficiency and lower resource consumption<br />

with practical examples from automated production in a<br />

wide field of applications.<br />

In focus: transparent processes<br />

SCHUNK showed a whole range of new products that contribute<br />

to a boost in efficiency. Among other things the PPD<br />

positioning unit made its debut, enabling more complex motion<br />

sequences in pneumatic handling. In conjunction with<br />

pneumatic grippers, gripper fingers can be controlled flexibly<br />

and with high precision, and gripping force and speed can be<br />

regulated. Required application parameters for defined gripper<br />

series are already stored on the unit – this saves time during<br />

commissioning. Combined with the power ful, pneumatic<br />

universal gripper PGL-plus-P with an extra-long stroke, versatile<br />

handling tasks can be realized even in demanding environments,<br />

from machine loading to highly sensitive cleanroom<br />

applications. As the first in the world the company offers<br />

the pneumatic gripper with a certified, secure GripGuard<br />

gripping force maintenance. It has an already integrated IO-<br />

Link sensor system that enables position sensing of the gripper<br />

fingers and thus saves on external sensors.<br />

Flexible from batch size 1<br />

Two new electric grippers set standards in terms of flexibi lity,<br />

interface diversity, and process reliability: the smart universal<br />

gripper EGU shows its strengths to the full in multi-variant<br />

machine loading, even under harsh conditions. With its large<br />

stroke and integrated gripping force retention it is able to<br />

reliably load and unload raw and finished parts of different<br />

sizes. It can be freely networked. The integrated gripping<br />

force maintenance and a StrongGrip mode for increased gripping<br />

force makes it an all-rounder for all handling tasks. Its<br />

counterpart for handling delicate, fragile parts in cleanroom<br />

areas is the smart EGK gripper for small components. With<br />

its SoftGrip mode it masters demanding and varied handling<br />

tasks in the laboratory industry or electronics manufacturing.<br />

Both grippers are offered with extensive function modules<br />

and commissioning plug-ins.<br />

Easy entry into intelligent handling<br />

For handling individual objects the user-friendly 2D Grasping<br />

Kit has been developed, randomly arranged on a single<br />

level, which makes it much easier to get started with automated<br />

object handling. The core of this intelligent system is<br />

SCHUNK presented a new generation of linear direct drive axes<br />

with the SLD series and therefore ensures short cycle times<br />

and more productivity<br />

the in-house developed AI software, which is pre-installed<br />

on SCHUNK’s own industrial PC (SVC). Since the market<br />

launch in 2022 the automation expert has further optimized<br />

the software and simplified the teaching and labeling of components.<br />

This coordinated complete package of hardware, soft<br />

ware and service comes from one source and can be used for<br />

all robots.<br />

Power through direct drive<br />

The first time presented dynamic linear direct axes SLD can<br />

handle higher load capacities, due to the profiled rail guide<br />

and compact design, having a long service life. With heavyduty<br />

axes equipped with electric linear direct drive, users<br />

achieve increased productivity in high-speed assembly and<br />

handling processes due to the short cycle times.<br />

The new flat ERT rotary units are also equipped with direct<br />

drive and offer a wide range of measuring system interfaces<br />

such as the HIPERFACE DSL® digital real-time interface and<br />

an electric holding brake. The unit can be used as a rotary<br />

table for components, assembly groups and tools, or as a rotary<br />

module in gantry solutions, as a rotary indexing table or a<br />

precise positioning module.<br />

Your partner when switching over to automation<br />

In order to successfully counter the shortage of skilled workers<br />

and pressure for efficiency and to accompany the change<br />

to digital, more sustainable manufacturing processes, the<br />

application expert offers a variety of automation approaches<br />

from a single source. The company demonstrates automation<br />

solutions for new, easy-to-integrate manufacturing<br />

and assembly processes that meet the requirements for precision,<br />

dynamics and reliability in different industries such as<br />

e-mobility and life science.<br />

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

no. 3, August <strong>2023</strong><br />


components<br />

When precision is of the essence<br />

The CNC dividing heads of the HOFMANN RWNC<br />

series have been known for their high precision since<br />

they were first launched. This is made possible through<br />

Rodriguez components that are used in the bearings of<br />

the dividing spindles. With new applications requiring<br />

even greater precision, the partners jointly developed<br />

an alternative solution: special high-precision bearings<br />

can meet the ambitious requirements.<br />

Hofmann is a well-known supplier of key components for the<br />

machine tool industry. The company manufactures all major<br />

components for dividing and rotary movements in its own<br />

modern manufacturing facilities. It focuses on tailor-made<br />

solutions that are impossible to achieve with standard solutions<br />

from other manufacturers. In addition to dividing units<br />

and rotary tables, the product range also comprises a wide<br />

range of coordinated accessories, including tailstocks and<br />

counter-supports for bracing long workpieces.<br />

Included in this range is the RWNC single-axis NC dividing<br />

unit, which is suitable for use with both vertical and horizontal<br />

rotary axes. The standard tip heights of the RWNC series<br />

are 75, 100, 125, 160, 220, 300, 380 and 400 mm. Special<br />

tip heights can be achieved by using bases or adapted housings.<br />

The hydraulic clamp of the dividing spindle enables<br />

high machining forces to be applied. It is also possible to use<br />

indirect or direct position measuring systems.<br />

Excellent radial and axial run-out<br />

as a unique selling proposition<br />

“The CNC dividers in the HOFMANN RWNC series are primarily<br />

distinguished by their mature, robust and stable design”,<br />

says Timo Conzelmann, head of design at Hofmann.<br />

“Coupled with exceedingly high accuracy values, the customer<br />

receives a reliable solution that is individually tailored<br />

to the respective application scenario.” The dividing heads<br />

are used primarily as a 4th axis on machining stations and<br />

on engraving, grinding or measuring machines. They feature<br />

a stable, vibration-free design and also stand the test of rough<br />

working conditions thanks to their robust construction.<br />

The Rodriguez rotary table bearings (RTB) are now<br />

also available in an HSA version<br />

image: Unitec | Rodriguez GmbH<br />

The Rodriguez components used in the bearings of the<br />

dividing spindles all contribute to the high precision of the<br />

CNC dividing units<br />

image: Werkzeugsysteme Müller GmbH<br />

The eccentrically adjustable worm drive of the dividing<br />

heads consists of a case-carburised worm shaft and a worm<br />

gear made of an extremely low-wear bronze alloy. Coupled<br />

with a high performance lubricant, it runs with very little<br />

fric tion and backlash, thus also consuming very little power<br />

compared to torque drives. “What is particularly noteworthy<br />

is the high level of accuracy”, emphasises Timo Conzelmann.<br />

“The outstanding radial and axial runout on the dividing<br />

spindle is due in part to the Rodriguez bearings.”<br />

New requirements for accuracy<br />

Up to now the drives of the dividing heads used a fourpoint<br />

Rodriguez bearing as the radial thrust bearing, whereas<br />

the tilting moment was supported on a radial ball bearing.<br />

This combination has proven itself over many years – but<br />

now there was a wish to achieve even higher levels of accuracy,<br />

which could not be achieved using the previous bearing<br />

arrangement.<br />

“Our dividing heads are used, among other things, for<br />

thread measurement in measuring machines”, explains Timo<br />

Conzelmann. “The workpiece is clamped between fixed tips<br />

in the dividing unit and tailstock.” For this the dividing unit<br />

is equipped with an optional dividing spindle with an Mk-2<br />

Morse taper. This application requires an elevated radial and<br />

axial run-out in the Morse taper of less than 0.006 mm – for<br />

comparison: Until now a maximum of 0.01 mm was the rule.<br />

In concrete terms, the specification given to Rodriguez was:<br />

the new version would have to achieve a runout of 0.005 mm<br />

in the Morse taper and on the gauging mandrel and a runout<br />

of 0.0025 mm on the dividing spindle face.<br />

Precise, very precise, high-precision bearings<br />

“In close cooperation with the customer we developed a new<br />

solution tailored to the new requirement profile”, explains<br />

Ulrich Schroth, key account manager for VAP at Rodriguez.<br />

44 no. 3, August <strong>2023</strong>

components<br />

“The dividing spindle is now supported in a spindle bearing<br />

arranged in an O arrangement in each case and held in place<br />

with a shaft nut.” The customer grinds the inside of the Mk-2<br />

Morse taper of the dividing spindle in its assembled state on<br />

the grinding machine driven by the dividing unit itself. This<br />

puts accuracy within this range.<br />

The dividing heads now use high-precision bearings from<br />

SKF’s “Super Precision Bearings” series, which Rodriguez has<br />

had in its range since 2020. These high-precision (axial) angular<br />

contact ball and cylindrical roller bearings are specially<br />

designed for the tough requirements of machine tools. They<br />

not only support high rotational speeds and payloads, but<br />

also run as stiffly and extremely accurately as possible and,<br />

last but not least, generate little heat and low levels of noise<br />

and vibration. They also have an impressively long service<br />

life, long maintenance intervals and low energy consumption.<br />

Large range of bearings for the machine tool sector<br />

“The high-precision bearings enable original equipment<br />

manufacturers and end users to further optimise the parameters<br />

of their systems and applications”, says Ulrich Schroth.<br />

“This can be very well demonstrated by the present application”.<br />

In the field of machine tools, the bearing arrangement<br />

of spindles and rotary or indexing tables is important for<br />

optimum force absorption and transmission. Thanks to its<br />

comprehensive range of precision rolling bearings, Rodriguez<br />

can optimally meet all requirements.<br />

High precision in use is usually of utmost importance.<br />

Bearing manufacturers are still making improvements in<br />

this respect. A further example of this are the Rodriguez rotary<br />

table bearing series (RTB), which have been available in<br />

a new version for some time. These high-precision solutions<br />

are particularly suitable for positioning rotary or indexing tables<br />

in machining stations. Now they are also available in an<br />

HSA version, which offers impressive stiffness, requires 20 %<br />

less starting and running torque and offers a 20 % increase in<br />

speed. Users also benefit from up to 70 % more moment rigidity<br />

and load capacity (both axial and radial). These significant<br />

improvements were achieved, among other things, through<br />

re-dimensioning of the RTB bearings by the manufacturer<br />

and an optimised production process.<br />

Breaking new ground<br />

together with the customer<br />

“In this case improved models and new software enabled a<br />

more accurate calculation”, concludes Ulrich Schroth. “Tests<br />

and developments in cooperation with selected customers<br />

also generated valuable experience and greater expertise in<br />

this field. I think that especially the latter is extremely important,<br />

beyond any trends: working out solutions that the market<br />

really needs, jointly with the customer.” This has always<br />

been Rodriguez’s philosophy – which is also reflected in the<br />

new version of the HOFMANN dividing head.<br />

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

Hello<br />

visitors!<br />

Welcome to the<br />

world’s leading trade<br />

fair for production<br />

technology.<br />

no.3, August <strong>2023</strong><br />


components<br />

New CAM software will drastically improve the way<br />

manufacturers operate their Laser machines<br />

GF Machining Solutions has launched a new version<br />

of a computer-aided manufacturing (CAM) software,<br />

LaserCAM, part of the LaserSUITE360 software package.<br />

At the EPHJ tradeshow in Geneva (Switzerland), GF Machining<br />

Solutions has introduced the new advanced software LaserCAM.<br />

LaserCAM, included in the LaserSUITE360 1.13.0<br />

software package, offers operators a completely new user<br />

inter face for creating and editing laser engraving and decoration<br />

designs easily. It provides improved calculation speeds,<br />

reducing the time required for programming and setup,<br />

Example of a micromachining application shown in LaserCAM<br />

and enables manufacturers to respond to changing production<br />

needs quickly and get their products faster to market.<br />

It is specifically designed for laser engraving, micromachining<br />

and decoration operations, with over a decade of experience<br />

in the field and promising to drastically improve the way<br />

manufacturers operate their laser machines. This will allow<br />

manufacturers in watchmaking who have been hesitant to do<br />

so to adopt laser machining for their applications.<br />

In addition to its existing engraving tools, LaserCAM includes<br />

unique features such as 3D finishing, blasting and<br />

watchmaking decoration functions, allowing manufacturers<br />

to create intricate and precise designs. The software has been<br />

developed with a novel modular architecture, which is a significant<br />

leap forward in user-friendliness. GF Machining<br />

Solutions will be able to expand the features in the coming<br />

versions, aiming to consolidate its leading position in micro<br />

cavity, semiconductor and hard material machining as well as<br />

watchmaking applications. LaserCAM is compatible with the<br />

entire range of GF Machining Solutions’ Laser ablation machines<br />

to meet the specific needs of every manufacturer.<br />

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

Strong all-in solution for efficient quality inspections<br />

The new ZEISS VoluMax 9 titan is compact design<br />

and powerful technology combined. The system comes<br />

with 450 kV, thus enabling reliable and consistent detection<br />

of defects in both large, high-density parts and<br />

complex multi-material assemblies with a size of up to<br />

590 x 700 mm.<br />

Dense parts are inspected at high resolution courtesy of<br />

1,500 W and a 3k-detector. Therefore ZEISS VoluMax 9 titan<br />

is suited for a broad range of applications that put all sorts<br />

of demands on efficiency and quality. Among the most common<br />

applications are battery modules and stators as well<br />

as turbine blades or electronic parts.<br />

ZEISS VoluMax 9 titan reliable high-resolution detection<br />

of defects in multi-material parts<br />

Volume Inspect – comprehensive workflow<br />

with a single software<br />

The connection of the new ZEISS VoluMax 9 titan to the<br />

ZEISS Quality Suite is one of the major advantages of the system.<br />

All steps in the inspection of parts – from operating the<br />

CT to inspecting high-resolution 3D volume data sets to creating<br />

and sharing the final report – can be performed with<br />

the Volume Inspect software solution. Next to maximum<br />

ease of use, the software integration offers access to various<br />

add-ons. For example, scanning processes can be optimized<br />

even further with ZEISS Automated Defect Detection<br />

(ZADD), an optional software solution for the AI-based,<br />

automated detection of defects.<br />

ZEISS VoluMax 9 titan – compact design and<br />

high performance combined<br />

ZEISS VoluMax 9 titan is extremely compact with its small<br />

installation area of no more than 2,750 x 2,350 x 1,750 mm. So<br />

the CT is ideally suited for installation in every quality laboratory<br />

or in close proximity to the production line. The integrated<br />

control panel and the improved axis system for easy<br />

loading ensures a high degree of flexibility and efficient operation<br />

in the smallest of spaces. ZEISS guarantees a long life<br />

cycle and a low maintenance level. Qualified service teams in<br />

more than two dozen countries stand ready for help.<br />

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

46 no. 3, August <strong>2023</strong>

EMO<br />

Digitalization and sustainability<br />

More than 1,750 exhibitors from 42<br />

countries are currently expected at EMO<br />

Hannover <strong>2023</strong>. They will present the entire<br />

spectrum of production technology.<br />

Major points of interest include machining<br />

centers and lathes, cutting tools and<br />

clamping devices, measuring equipment<br />

and control systems. “The breadth of the<br />

technical offerings is unparalleled at the<br />

international trade fair for production<br />

technology,” emphasized Markus Heering,<br />

executive director of the VDW.<br />

The event highlights the challenges that exist<br />

in production: greater efficiency, more flexibility,<br />

better quality, increased accuracy, the<br />

integration of AI, comprehensive factory-wide<br />

networking and much more besides.<br />

EMO Hannover is offering various joint<br />

stands aimed at drawing attention to specific<br />

trend topics: additive manufacturing, connectivity,<br />

cobots and sustainability in production.<br />

“In particular, latest developments such as<br />

those showcased in the sustainability in production<br />

area are attracting a lot of interest, as<br />

exhibitors are keen to reposition themselves<br />

in this field,” reported Wilfried Schäfer, executive<br />

director of the VDW. Research institutes<br />

will also feature prominently on the stand, using<br />

it to present their sustainability projects.<br />

Trend forum for the future of production technology<br />

As the world’s leading trade fair for production technology, EMO Hannover<br />

aims to cover all the important topics relating to the industrial value chain,<br />

to present the current state of the art and to highlight possible scenarios for<br />

future development. “In addition to the aforementioned topics, a further<br />

focus will be on the recruitment of skilled workers on the special training<br />

stand.”<br />

The special umati stand will feature a major live demonstration aimed at<br />

showcasing the latest developments in the connectivity initiative for the mechanical<br />

and plant engineering industry as a basis for effective networking<br />

within and between factories. Finally, the startup area will be promoting<br />

pioneering collaboration with young companies, said Schäfer, describing two<br />

further examples.<br />

The joint stands will be complemented by two forums in halls 9 and 16<br />

of the Hannover exhibition center. They provide a platform for exhibitors’<br />

presentations on technology topics and for in-depth presentations on special<br />

future insights topics.<br />

The program includes a conference on business opportunities in the Indian<br />

market, and two half-days entitled “New digital work – opportunity or<br />

disenfranchisement?” Both go into greater depth on individual aspects of the<br />

business in future.<br />

Further future of connectivity half-days will address the topics of umati<br />

and energy efficiency through digitalization. Sustainability in production<br />

aspects will finally be covered in presentations and discussions on e-mobility,<br />

climate-neutral production, the potential of circular business models and<br />

best practices with regard to sustainability in production.<br />

VDW hall 8, booth B53 / umati hall 9, booth F24<br />

further information: www.emo-hannover.de<br />

High level of innovation with<br />

six-sided complete machining<br />

Anyone using EMO as an opportunity<br />

to discover any kind of innovation for<br />

their company will find satisfaction with<br />

the CHIRON Group.<br />

If one is familiar with the world of six-sided<br />

complete machining with milling and turning,<br />

one knows about the benefits when machining<br />

highly precise, complex and thus often very expensive workpieces. Even the<br />

very first produced part must have the correct dimensions. The MT 715 two+<br />

and the FZ 08 S mill turn precision+ stand up to these demanding requirements<br />

at the fair. The machining centers will show why the six-sided complete<br />

machining system with integrated automation always means a productivity<br />

boost for customers.<br />

Micro5: the number one in micro-machining<br />

In a very short amount of time, the smallest and most energy-efficient machine<br />

from the CHIRON Group has become a bestseller. The USPs of the<br />

Micro5 are sustainable and ultraprecise, with an energy requirement of just<br />

0.5 kW/h, size of under 1 m 2 and micron-level precision. Together with the<br />

automation Feed5, the Micro5 features high autonomy. With a workpiece<br />

blank of 50 x 50 x 3 mm (capacity of over 1,200 blanks) and an assumed cycle<br />

time of 10 min, that equates to eight days of automated production.<br />

hall 12, booth C50<br />

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

no. 3, August <strong>2023</strong><br />


EMO<br />

Powerful and productive<br />

New 5-axis machining center F 6000 from HELLER<br />

At EMO <strong>2023</strong> HELLER will present the new generation<br />

of its F 6000 machining center for the first time.<br />

The 5-axis machine with head kinematics was designed<br />

from the ground up for flexible series production.<br />

Like all HELLER machines, it sets a benchmark for cutting<br />

performance and precision, including free chip fall, short<br />

idle times, optimum automation capability and compatibility<br />

with the H and FP series for a wide range of workpieces. The<br />

F 6000 also scores with first-class equipment and expandability<br />

with technologies such as mill-turn, interpolation turning<br />

or power skiving. The team led by HELLER’s head of development,<br />

Dr. Manuel Gerst, kept a close eye on these topics, as<br />

well as consistent standardisation and the use of key components<br />

‘Made by HELLER’.<br />

Highlights of the new generation include the completely<br />

redesigned swivel heads and the new integrated motor spindles<br />

specially developed by HELLER. The spindle units deliver<br />

the highest levels of precision, dynamics and cutting performance<br />

for 5-axis machining.<br />

For combined milling and turning operations, the machine<br />

is equipped with the optional Mill-Turn function, in which<br />

the high-torque DDT (Direct Drive Turning) rotary table<br />

plays a key role. In line with the trend towards complete machining<br />

this eliminates the need for reclamping on separate<br />

turning machines. The results are improved workpiece accuracy<br />

and significantly reduced cycle times, especially for series<br />

products. The pallet changer is included as standard as<br />

the first level of automation. The new ‘Automation ready’ option<br />

enables easy integration of the HELLER rotary pallet<br />

storage (RSP) and HELLER’s standardised linear magazine<br />

solutions at a later date.<br />

HELLER will present for the first time the new generation<br />

of its F 6000 machining center<br />

For maximising in day-to-day production, HELLER’s design<br />

engineers have focused on clear and easy operation as<br />

well as good accessibility to all work areas. The new Siemens<br />

SINUMERIK ONE control fitted as standard and the convenient<br />

control unit in panel design with 24” touch screen make<br />

operation easy. At the same time, increased access to the<br />

work area and the optional new SETUP-Assist make it easier<br />

to set up processes on the machine.<br />

At the heart of HELLER’s trade show appearance will be<br />

360° performance – a holistic view of the requirements of<br />

modern production. To achieve this, HELLER focuses on five<br />

solution areas. In addition to the F 6000, HELLER will be<br />

presenting products for the digitisation of production, a comprehensive<br />

range of services as well as innovative manufacturing<br />

processes and technologies for complete machining on<br />

a single machine.<br />

hall 12, booth C68<br />

further information: www.heller.biz<br />

“Diamond purchases are a matter of trust”<br />

At EMO in Hanover LACH DIAMANT can now<br />

look back on 100 years of existence after it was founded<br />

by Jakob Lach in 1922.<br />

At the moment, it is a timeline of international pioneering<br />

anniversaries, for example<br />

→ 1969 the first CBN Borazon® grinding wheel, 55 years ago<br />

→ 1973 introduction of the first polycrystalline<br />

diamond cutting tools – exactly 50 years ago<br />

→ 1975 first CBN cutting tools – 48 years ago<br />

→ 1978 spark erosion was discovered for the production of<br />

polycrystalline diamond tools and registered for patent –<br />

45 years ago<br />

Everything you will see at EMO, proven and new, is built on<br />

the discoveries, developments, and accumulated knowhow of<br />

the company.<br />

LACH DIAMANT is a partner to manufacturers of wind<br />

power systems, the aircraft and automobile industry and its<br />

suppliers, toolmaking (composite, plastic, graphite) and tool<br />

manufacturing industries, electrical and medical industries<br />

and many other industries.To this day it’s focus is still<br />

on “custom made”, and shows the versatility of the company’s<br />

product portfolio, originating from its headquarters in<br />

Hanau.<br />

By the way, last year our subsidiary in Grand Rapids/<br />

Michigan, USA, celebrated its 40 th anniversary as independent<br />

manufacturer of PCD<br />

cutting tools for the<br />

American market, and<br />

continues to strive to<br />

equal LACH DIAMANT<br />

Germany.<br />

hall 4, booth D48<br />

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

48 no.3, August <strong>2023</strong>

EMO<br />

The customer-oriented REvolution continues<br />

At EMO in Hanover STUDER will present a new<br />

automation solution at the joint stand of the UNITED<br />

GRINDING Group. Fritz Studer AG, one of the market<br />

and technology leaders in universal, external, internal<br />

cylindrical, and non-circular grinding, will present a<br />

new automation solution on the S31 universal external<br />

cylindrical grinding machine at EMO <strong>2023</strong><br />

Additionally visitors can look to other machines on display:<br />

• favorit – the price hit for the most important applications<br />

• S33 with uniLoad – the value for money<br />

for individual requirements<br />

• S100 – the ergonomic machine for the entry-level segment<br />

• S131R with roboLoad – the expert for every conceivable<br />

internal grinding task<br />

With the first-time presentation of C.O.R.E. at EMO 2021<br />

in Milan, the UNITED GRINDING Group has triggered a<br />

revolution in the field of machine tools. The advanced hardand<br />

software architecture on which C.O.R.E. is based enables<br />

a novel machine interaction concept.<br />

But C.O.R.E. is much more than just a revolutionary operating<br />

system. It opens up new possibilities for networking,<br />

controlling, and monitoring the production process and<br />

thus for process optimization. It also lays the foundation for<br />

the operation of modern IoT applications and thus opens<br />

the door to the digital future.<br />

hall 11, booth E34<br />

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

Meeting complex challenges with smart solutions<br />

At EMO Schwäbische Werkzeugmaschinen GmbH<br />

(SW) will present two new products: the two-spindle<br />

BA W03-22 CNC machining center and the BA profile,<br />

a new machine concept for machining profiles.<br />

Furthermore, SW will be showing the BA space3, currently<br />

its largest machine for machining battery housings, and will<br />

be offering insights into current trends in manufacturing<br />

such as friction stir welding and giga casting.<br />

“Innovate Manufacturing” is the theme of this year’s EMO,<br />

which also captures the very essence of SW’s “Smart Manufacturing<br />

Solutions” corporate claim. “For us innovative and<br />

smart manufacturing are two sides of the same coin,” says<br />

André Harter, head of marketing and business development<br />

at SW. “Both allow us to respond individually and efficiently<br />

to our customers’ needs. At EMO Hannover we also want to<br />

reinforce our ‘Be smart. Be part’ theme. This applies not only<br />

to sustainability, which we are driving forward at SW with<br />

our ECO2 machining programme. It also applies to our technology<br />

people. They are at the heart of our vision and our<br />

smart solutions.” The market leader for multi-spindle machines<br />

will be exhibiting three machines from its extensive<br />

range of smart manufacturing solutions, two of them for the<br />

first time.<br />

Efficiency boost for the automotive industry<br />

Productivity, flexibility, modularity, and connectivity: these<br />

are the most important factors for SW when it comes to<br />

meeting challenges with efficient system solutions in the<br />

fast-growing field of e-mobility. Case in point is the new<br />

BA W03-22 CNC machining center. Thanks to its high precision<br />

and efficiency, this two-spindle machine is ideal for producing<br />

high-quality workpieces in medium and large series<br />

for the automotive industry. Compared to a single-spindle<br />

machine, cycle times can be reduced many times over, ensuring<br />

maximum productivity. “We have expanded the<br />

Smart Manufacturing Solutions from SW offer increased<br />

productivity, flexibility, modularity and connectivity<br />

proven machine concept of the model 3 series to include a<br />

two-spindle, double-station machine. It allows for faster axis<br />

accelerations with the linear motors installed in the machine,”<br />

explains Harter. “As a result we achieve more power and<br />

speed compared to a ball screw as in the BA 322 model, for<br />

example with 20 % faster chip-to-chip times.” With 300 mm<br />

of travel, the BA W03-22 also positions in G0 30 % faster than<br />

the BA 322. The machine is the first from SW to be equipped<br />

with Siemens Sinumerik One control.<br />

Flexible machining with BA profile and BA space3<br />

Another highlight is the new BA profile. Featuring a compact<br />

design, the two-spindle machine has two operating areas and<br />

allows machining on two worktables per side. It can be loaded<br />

either via automation or ergonomically by hand.<br />

hall 12, booth C04<br />

further information: www.sw-machines.com<br />

no. 3, August <strong>2023</strong><br />


EMO<br />

Smart sensor technology<br />

Integrated solution for the factory of the future<br />

With its intelligent components, the Smart<br />

Automation and Monitoring System (SAMS) by Balluff<br />

provides important information about the condition<br />

and control of machines and entire systems. The portfolio<br />

is extensive, with a focus on the integration of<br />

software and hardware.<br />

Small batch sizes, different types of parts, external influences<br />

and time-consuming error search on production lines: the<br />

challenges for users in manufacturing and logistics companies<br />

are increasing. Possible consequences include long setup<br />

times, downtime and production loss. At the same time the<br />

importance of efficiency and effectiveness in industrial automation<br />

is growing. This is where the Smart Automation and<br />

Monitoring System (SAMS) by sensor and automation specialist<br />

Balluff comes in. With intelligent devices, it provides<br />

important data about the condition of individual machines<br />

and entire systems. Smart functionalities also enable various<br />

automation tasks to be solved directly in the sensor, eliminating<br />

a controller, as data preprocessing already takes place in<br />

the sensor itself.<br />

Capture, analysis and diagnosis<br />

Smart, powerful sensors and network components form the<br />

core of the system. The SAMS portfolio includes various<br />

URMA AG has been a drilling expert in the field of precision<br />

tools for over 60 years. Under the motto “Innovation is our<br />

tool”, the family-owned company with its production site in<br />

Rupperswil (Switzerland) develops and manufactures preciproducts<br />

such as optoelectronic sensors, digital position indicators,<br />

inductive sensors, identification systems and IO-link<br />

masters. These can be individually programmed, configured,<br />

and easily implemented. Once attached to machines and<br />

equipment, the sensors continuously capture important measurement<br />

values such as vibration, temperature or exceptional<br />

environmental conditions. “Possible deviations and trends<br />

are recognized and analyzed in the subsequent comprehensive<br />

data analysis and diagnosis, with logical connections being<br />

directly inferred,” explains Dennis Seng, automation solution<br />

manager at Balluff. “The gathered information from<br />

cross-machine monitoring helps to identify or even prevent<br />

potential malfunctions, enabling timely responses and alleviating<br />

the burden on the control level.”<br />

Focus on smart factory<br />

Combining classic automation technology (OT) and information<br />

technology (IT): the Smart Automation and Monitoring<br />

System (SAMS) stands for the comprehensive automation<br />

philosophy of the company from Neuhausen auf den Fildern –<br />

and paves the way to the intelligent factory in times of the<br />

Industrial Internet of Things (IIoT).<br />

hall 9, booth F23<br />

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

Precise, process-reliable and efficient milling<br />

URMA AG is expanding its precision tool range<br />

with the diamond-tipped MX diamond shoulder<br />

and face shell mill tool, which is suitable for machining<br />

light metals such as aluminum. Here, too, URMA<br />

relies on the patented quick-change system, which<br />

promises the best handling and maximum precision.<br />

MX diamond is available in three different diameters:<br />

63 mm, 100 mm and 125 mm<br />

sion tool systems that are used worldwide in the mechanical<br />

engineering, automotive, hydraulics and aviation industries.<br />

The market for light metal workpieces and their machining<br />

tools is constantly growing. The use of known shoulder<br />

and face mill tools works, but the handling is complex and<br />

time-consuming. The company has applied its vast experience<br />

in the application of high-precision quick-change cut-off<br />

points. The result: MX diamond is a completely new shoulder<br />

and face shell mill system. With this modular cutting tool,<br />

URMA relies on the proven and highly precise RX quickchange<br />

cut-off point, which guarantees perfect axial run-out<br />

without needing subsequent correction when changing cutting<br />

edges. The teeth of the solid carbide cutting edge body<br />

are fitted with up to 20 PCD (polycrystalline diamond) tips<br />

and are ideally suited for machining lightweight materials<br />

such as aluminum, magnesium, copper-containing metals<br />

without iron, composites and fiber-reinforced plastics. This<br />

latest generation of face milling ensures lean production processes<br />

and automated production. Thanks to the high tool rigidity<br />

of the MX diamond, both finishing and roughing cuts<br />

can be made with the same cutting edge. With a feed rate of<br />

0.05 - 0.3 mm per tooth and a cutting speed of up to 5000 m/<br />

min, MX diamond is ideal for series production. Various geometries<br />

are available to meet individual requirements.<br />

hall 5. booth A63<br />

further information: www.urma.ch<br />

50 no. 3, August <strong>2023</strong>

EMO<br />

Machining center with tilting table<br />

for enhancing precision manufacturing<br />

The FEELER VUX 400 4/5-axis machining center designed to<br />

meet the diverse machining demands and applica tions. With its<br />

multi-axis capability, it surpasses three-axis machines and enables<br />

machining of special angles and complex multi-curved workpieces.<br />

The machine is suited for various industries, including:<br />

→ automotive industry: machining automotive parts, eg. cylinder heads<br />

→ medical industry, eg. orthopedic devices<br />

→ mold and die industry: machining precision molds and dies<br />

→ energy industry: machining components for power generation equipment<br />

• X/Y/Z axes travel: 650/520/480 mm<br />

• A(B)/C axes rotation angel: +30 ~ -120 °/360 °<br />

• table size:<br />

0350 mm<br />

• spindle speed:<br />

DDT 12000 rpm<br />

• X/Y/Z axes rapid traverse: 30/36/30 mm<br />

• number of tools: 24 T<br />

The machine’s boasts a range of key features that enhance its performance<br />

and versatility. It offers one-time workpiece clamping and positioning, enabling<br />

streamlined machining processes with reduced processing time and<br />

repetitive positioning. Additionally it excels in machining undercut areas,<br />

eliminating the need for additional forming tools and expanding its capabilities<br />

for complex surface machining applications.<br />

Capable to process deep hole molds, the machine not only reduces tool<br />

wear but also doesn’t need any special fixtures, resulting in cost optimization.<br />

The FEELER VUX 400 incorporates improved cutting tool rigidity by<br />

reducing tool length, leading to enhanced cutting performance, extended<br />

tool life, and superior surface roughness. These combined features make the<br />

VUX 400 an exceptional choice for precision manufacturing needs.<br />

hall 12, booth B68<br />

further information: www.ffg-ea.com<br />

EDM wire machines from € 3 / hour operating costs<br />

Ageltech GmbH is a manufacturer<br />

and supplier of electro-erosion machines<br />

and CNC diamond wire saws with an<br />

outstanding price-performance ratio.<br />

The EDM machine supplier also has a M-series<br />

in its range, spark erosion wire machines<br />

based on molybdenum wire technology. The<br />

simple and clearly designed machines feature<br />

outstanding operating costs from less than<br />

€ 3 / hour incl. depreciation and amortization<br />

over 5 years with € 25 k acquisitions costs. Molybdenum wire technology is<br />

little known in Europe, but all the more so in Asia. Well over half of the wire<br />

erosion machines there work with molybdenum wire technology. In general<br />

this technology is suitable for cutting conductive materials, e.g. from the<br />

usual large vehicle parts (also made of aluminum) to tools made of steel (including<br />

carbide steel) to small medical products made of special alloys.<br />

Ageltech offers very affordable entry-level machines with manual wire<br />

threading. It is most advantageous for works with either long, continuous<br />

eroding or where the eroding path can be eroded briefly into the workpiece<br />

from the outside, i.e. without a starting hole. Cutting contour accuracies up<br />

to +/- 10 µm and roughness up to Ra 0.8 µm display the impressive quality<br />

possibilities.<br />

The molybdenum wire technology achieves cost advantages mainly<br />

through the multiple reuses of the wire. It is rolled up and down during the<br />

process. This can be done for several working shifts with the same wire, with<br />

one winding usually being just under 200 m.<br />

Another source of the cost advantage is the simple rinsing of the wire with<br />

a water-based antioxidant agent instead of the usual technology in an immersion<br />

bath. The workpiece remains in the air and only the sparking area<br />

being machined is flushed. The whole handling is easy and machines are<br />

available from R&D applications to industrial mass production.<br />

The M-series is available in many sizes from working areas of<br />

320 x 450 x 200(h) mm³ up to 1,300 x 1,900 x 500(h) mm³. Special sizes on<br />

request.<br />

hall 6, booth C51<br />

EDM wire machine M200<br />

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

no. 3, August <strong>2023</strong><br />


EMO<br />

Ready to lead the future of machining solutions<br />

The machine tool manufacturer<br />

SORALUCE will demonstrate at EMO<br />

<strong>2023</strong> its international leadership in<br />

milling, boring, multitasking and automated<br />

solutions, presenting the New<br />

Performance Line, the New Generation<br />

of Heads, and also the most competitive<br />

technologies and services.<br />

SORALUCE has taken another step forward<br />

to extend its range of milling, boring, multitasking<br />

and automated solutions. The machine tool manufacturer has now<br />

added a new line of milling machines to its product portfolio to help furnish<br />

a response to challenges in the sector, offering added-value solutions in the<br />

most demanding industrial environments.<br />

The new Performance Line provides the highest reliability and precision<br />

along with an outstanding flexibility for medium/large workpieces.<br />

A common structure, three different types of architecture and countless<br />

solutions to adapt to the needs of each of the customers in the most competitive<br />

manner possible.<br />

Each of these families caters for several models and setups (fixed table,<br />

rotary table, multitasking), producing machines that can be configured<br />

for different work environments. These are three ranges sharing the main<br />

machine features, such as the column, saddle, ram and heads, built on the<br />

principle of modular design, to give high reliability, easier service and flexibility<br />

to devise a solution for the customer.<br />

Performance Line has the same design principles as SORALUCE’s heavyduty<br />

machine range: Soraluce Winning Combination, providing the most<br />

rigid and dynamic solution available on the market, with a combination of<br />

a cast iron structure, linear guides and active/passive damping technology.<br />

It applies all the experience the manufacturer has gleaned from its larger<br />

models, and has chosen the solution to offer more precision and reliability:<br />

direct drive inline motor with high power and torque in the ram, equipped<br />

with a 32 kW motor capable of reaching rpms up to 8000. The motor is<br />

water-cooled to boost thermal stability and secure the best precision machining<br />

results.<br />

hall 13 booth B30<br />

further information: www.bimatec-soraluce.de<br />

Metallurgical solutions combining performance,<br />

longevity and reliability<br />

Erasteel, world leader in Powder<br />

Metallurgy High-Speed Steels for over<br />

50 years which provides solutions combining<br />

performance, longevity and reliability,<br />

is about to launch a new product<br />

BlueTap®Max dedicated to high-performance<br />

taps<br />

Thanks to a long-standing know-how, a longterm<br />

partnership with customers and a highly<br />

qualified R&D team, Erasteel offers ever more<br />

innovative, high-performance, and sustainable<br />

Powder Metallurgy (PM) High-Speed<br />

Steels (HSS) grades.<br />

Only player in the world dedicated to High-<br />

Speed Steels and major player in strategic<br />

metals recycling, Erasteel is:<br />

→ world leader in Powder Metallurgy High-<br />

Speed Steels for over 50 years: the premium<br />

ASP®, PEARL® and BlueTap® ranges<br />

provide its customers a long-term solution with longer lifetime, better<br />

performance and lower maintenance.<br />

→ major international player in sustainable Powder Metallurgy and<br />

conventional High-Speed Steels: Erasteel offers high-performance<br />

products made from over 92 % recycled materials and aims to become<br />

very soon the first producer to reach 100 % recycled HSS<br />

→ European leader in the recycling of batteries and oil catalysts by<br />

pyrometallurgy: thanks to a unique process in the world, Erasteel<br />

provides a second life to strategic metals with high added value<br />

contributing to preserve natural resources.<br />

Innovation is in the company’s DNA: Erasteel provides global industry with<br />

metallurgical solutions that comply with the new challenges of market demand<br />

evolution.<br />

In September at EMO the company will announce the launch of a new<br />

grade for high-performance taps named BlueTap®Max. BlueTap®Max increases<br />

significantly hardness and grindability thanks to a unique concept of<br />

powder-metallurgy alloys. These unprecedented technical properties deliver<br />

unrivalled performances with optimized total cost of ownership.<br />

hall 4, booth G33<br />

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

52 no. 3, August <strong>2023</strong>

EMO<br />

Highest precision with extra technology<br />

At EMO <strong>2023</strong> Kern introduces for the<br />

first time the advanced five-axis machining<br />

center Kern Micro HD with a new<br />

Fischer CSC spindle and high-end control<br />

Heidenhain TNC 7. Furthermore<br />

visitors can engage with Kern Micro<br />

HD and with the laser machining center<br />

Kern Femto E3.<br />

Visitors will see three precision machines.<br />

Among the precision machines, they can also<br />

find many individual innovations, with which<br />

the Kern Micro HD can be equipped in the<br />

future. Just one example: the highly effective<br />

shaft cooling of the new CSC HSK 40 spindle<br />

reduces the previously required warm-up<br />

time to almost zero.<br />

The company’s experts and advisors will be explaining the resulting opportunities<br />

for applications as well as the technical background of all displayed<br />

parts. Visitors can look forward to experiencing the Kern Micro HD,<br />

which was launched in 2020 and is now very popular with more than 150 installed<br />

machines worldwide. Eight different sample parts in different materials<br />

will be machined. Extremely hard and softer metals as well as ceramics<br />

and graphite. The machining center proves its versatility and reliability when<br />

it comes to precision and surface quality in the µm area.<br />

As a third machine Kern Microtechnik will present the laser machining<br />

center Kern Femto E3. It will machines in regular intervals heading tools for<br />

cutting inserts. The advantage of laser machining is the lack of tool costs and<br />

the stability of the process, while achieving accuracies of +/-3 µm and surface<br />

qualities of Ra = 0,1 µm. Other applications for this technology are for example<br />

surface texturing and applications in mold & die.<br />

hall 12, booth D60<br />

further information: www.kern-microtechnik.com<br />

Small differences that make a big impact<br />

Oerlikon Balzers, a leading global<br />

technology brand of the Oerlikon Group,<br />

will showcase its latest high-tech surface<br />

solutions at EMO. The S3p coating<br />

BALIQ TISINOS PRO for hard machining<br />

up to 70 HRC will be shown for the<br />

first time, while other highlights include<br />

the carbon coating BALINIT MAYURA,<br />

the diamond coatings from the BALDIA<br />

family and advanced digital production<br />

and connectivity technologies.<br />

Products and services from the sister brands<br />

Oerlikon Metco and Oerlikon AM complete<br />

the trade fair line-up, where the theme is<br />

“Small difference, big impact”.<br />

In a milling test, the innovative<br />

BALIQ TISINOS PRO coating achieved up to<br />

50 % longer service life than its predecessor<br />

Improved performance in machining hardened and stainless<br />

steels and high-temperature alloys<br />

BALIQ TISINOS PRO, the latest coating innovation from Oerlikon Balzers,<br />

clearly demonstrates how small differences can have a big impact. BALIQ<br />

coatings are based on the S3p (Scalable Pulsed Power Plasma) coating technology,<br />

which combines the advantages of arc evaporation and magnetron<br />

sputtering processes to push the boundaries of conventional HiPIMS coating<br />

performance. The microstructure and smoothness of BALIQ TISINOS PRO<br />

have been further enhanced, resulting in even better wear resistance. When<br />

machining high-temperature alloys and stainless and hardened steels up to a<br />

hardness of 70 HRC, the AlTiSiN coating withstands high thermal loads and<br />

ensures an even more stable process. Tests with end mills have shown an average<br />

increase in tool service life of up to 50 % compared to its predecessor<br />

coating with higher production quality, particularly in micro-machining.<br />

Carbon and diamond coatings for non-ferrous metals,<br />

lightweight construction and more<br />

Introduced in 2022, BALINIT MAYURA is attracting increasing attention,<br />

and not just because of its rainbow color. The thin and extremely hard<br />

ta-C coating for machining non-ferrous materials such as aluminum, copper,<br />

brass alloys and polymers minimizes material build-up on the tool while<br />

maintaining extremely sharp cutting edges. High precision, longer tool service<br />

life and increased productivity are the reasons why toolmakers and end<br />

users are increasingly turning to BALINIT MAYURA.<br />

The BALDIA family from the company serves innovative markets such as<br />

the dental, automotive, and aerospace sectors but also traditional industries<br />

like mold making. These CVD diamond coatings are ideal for the highly<br />

abrasive machining of graphite, ceramics or CFRP/GFRP materials, supporting<br />

sustainable manufacturing solutions in electromobility and lightweight<br />

construction. For example, BALDIA COMPOSITE DC has tripled the tool<br />

service life of CFRP drills in aircraft construction while reducing tool costs<br />

by more than half.<br />

hall 4, booth B18<br />

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

no. 3, August <strong>2023</strong><br />


EMO<br />

Effortless start into automated quoting<br />

Spanflug Technologies will present its<br />

quoting solution in its latest version at<br />

EMO. The cloud-based software aims to<br />

streamline the otherwise complex and<br />

tedious process of preparing quotes for<br />

custom turning and milling parts and reduces<br />

efforts by up to 90 %.<br />

It addresses the challenges faced by machine<br />

shops, such as excessive time and cost spent<br />

on administrative tasks, increasing competitive<br />

pressures and uncertainty resulting from<br />

the growing complexity in stocks procurement.<br />

With its industry-leading, innovative<br />

algorithm, Spanflug Make sets new standards<br />

in automated quoting.<br />

Seamless digital solution from CAD<br />

model to ready-to-send customer<br />

quote<br />

With Spanflug Make machine shops calculate<br />

prices for turning and milling parts in one<br />

minute. The software supports throughout the<br />

entire quoting process – from receiving RFQs<br />

to sending out final quotes to customers.<br />

Main features of Spanflug Make include:<br />

→ the software technology automatically extracts<br />

all data for manufacturing from CAD<br />

models and technical drawings, which users<br />

can securely upload; the smart parts analysis<br />

eliminates manual data entry and enables<br />

also unskilled employees to prepare precise<br />

customer quotes easily and autonomously<br />

umati is back<br />

At EMO Hannover <strong>2023</strong> it can be<br />

stated: umati is back! And bigger and<br />

more comprehensive than ever before. In<br />

Hannover, the community of now more<br />

than 300 umati partners will demonstrate<br />

live how easily decentralized communication<br />

between machines, components<br />

and software works – and well beyond<br />

the machine tool.<br />

umati (universal machine technology interface)<br />

is the global initiative for open communication<br />

interfaces for the machine building<br />

industries and their customers. Machine<br />

builders, software manufacturers, component<br />

suppliers and users have uniting forming<br />

a strong community to promote the use of<br />

open, standardized interfaces based on OPC<br />

UA companion specifications. umati ensures<br />

their identical implementation, provides a<br />

platform for exchanging experiences, creates<br />

→ prices and manufacturing times are automatically calculated by the<br />

intelligent algorithm, which has been tested and is subject to continuous<br />

AI-based and data driven improvements; it also includes up-to-date prices<br />

for nearly 60 materials and over 30 post-treatments, reducing uncertainty<br />

in supply chains and achieving the calculated margins despite price<br />

fluctuations; details like machining times, stocks or tools needed, are<br />

also provided and support machine shops in manufacturing planning<br />

→ immediate use or customized for the individual machine shop in just<br />

a few simple steps by setting up CNC machines and adjusting settings<br />

such as cutting values or markups<br />

→ Spanflug Make increases the efficiency of the entire quoting process; suiting<br />

a wide range of operational settings – from companies with established<br />

IT systems to smaller machine shops at the beginning of their digitization<br />

journey; with possibilities to manage customer master data directly within<br />

Spanflug and to either export calculation results to existing ERP systems<br />

or to conveniently generate a quote.<br />

→ Spanflug Make is a software-as-a-service solution that can be used<br />

without installation and maintenance efforts, calculating five parts per<br />

month is permanently free, while monthly or annual software<br />

subscriptions are available for unlimited calculations<br />

hall 9, booth H22<br />

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

visibility in the market and demonstrates the added value in a practical way.<br />

Meanwhile more than 300 umati partners participate in the umati community.<br />

More than 50 % are companies or institutions abroad, and 80 % are corporate<br />

partners. This makes umati truly a global initiative by companies for<br />

companies, and the only initiative that provides a live demonstration of the<br />

concrete exchange of data in a shared, globally available data ecosystem.<br />

The central point of contact at EMO will be the umati booth in hall 9, F24.<br />

Meet-the-experts sessions will be held several times a day. Interested parties<br />

can obtain first-hand information from the umati team and representatives of<br />

umati partner companies about the background, technology and benefits of<br />

open, standardized data interfaces for mechanical engineering. With the help<br />

of various exhibits it will be demonstrated how mature the technical solutions<br />

have become. In the immediate vicinity are the booths of the OPC<br />

Foundation and the Machine Information Interoperability (MII) department<br />

of the VDMA. This represents the strong triad of OPC UA as a base technology,<br />

the Gobal Production Language driven by VDMA in the form of OPC<br />

UA companion specifications for the numerous technologies of machine and<br />

plant engineering, and umati for implementation and marketing.<br />

hall 9, booth F24<br />

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

54 no. 3, August <strong>2023</strong>

An impressive lineup of machines and solutions<br />

EMO<br />

DN Solutions unveils 19 advanced<br />

ma chine tools at EMO Hannover, an impressive<br />

lineup of machines and solutions<br />

across three sections: Flexible Automation,<br />

Real Digitalization, and Green<br />

Forward.<br />

In the Flexible Automation section, DN<br />

Solutions will demonstrate more advanced<br />

automation solutions in collaboration with<br />

various companies specialized in automation,<br />

including robot automation. Visitors will witness<br />

the seamless integration of various work<br />

handling solutions, such as robots, gantry systems<br />

and pallet handling solutions, into its<br />

advanced machine tools. The section will exhibit<br />

automation solutions that utilized the<br />

compact turning center LYNX 2100LSYB and<br />

the collaborative robot COBOT, and automation<br />

solutions that apply the gantry loader to<br />

the high-productivity two-spindle horizontal<br />

turning center PUMA TW2600M. DN Solutions<br />

will boast of its technological prowess,<br />

with expanded automation area, such as applying<br />

the rotary pallet system to the highproductivity<br />

horizontal machining center<br />

NHP 5000 and applying AWC to<br />

the compact 5-axis vertical machining<br />

center DVF 4000.<br />

In the Real Digitalization section,<br />

DN Solutions will introduce<br />

smart manufacturing solutions<br />

based on user-friendly digital<br />

transformation technology. DN<br />

Solution will actively emphasize<br />

the benefits of digital twin technology,<br />

such as minimizing risks through virtual verification and reducing<br />

machine setup time. With multi-tasking machining turning center<br />

SMX3100ST, DN Solutions will also exhibit the skiving machining technology<br />

using the table turning function. Additionally, live machining demonstrations<br />

will be conducted, carefully selecting machining items to effectively<br />

showcase the unique features and characteristics of each machine.<br />

The Green Forward section will exhibit the energy-saving solutions of DN<br />

Solutions, which lead environmental protection, such as the mist-free solution<br />

for oil mist purification, the power consumption monitoring system.<br />

Specifically the mist-free solution offers the advantage of minimizing motor<br />

power, resulting in reduced power and maintenance costs. In pursuit of this<br />

goal the solution is designed to be compact, transitioning from a factory unit<br />

to a machine tool unit.<br />

hall 14 booth D06<br />

further information: www.dn-solutions.com<br />

Manufacture more parts faster<br />

The skilled labor shortage, disruptions<br />

in supply chains and rising costs for mate -<br />

rials and energy are affecting manufacturing<br />

companies involved in machining.<br />

That is why industry is searching for ways<br />

to improve efficiency and flexibility in<br />

order to manufacture more parts faster,<br />

resulting in that more machines need to<br />

be operated by fewer employees.<br />

This solution is reinforced by increasing automation<br />

with pallet changers or handling<br />

A CAD/CAM process helps to program complex<br />

machine tools with multiple spindles, tool<br />

carriers or units: here, parting off the workpiece<br />

and transferring it to the second spindle<br />

systems. Machining centers need to be operated unattended, so that employees<br />

can manage these tasks. The machine needs an NC program that covers<br />

all operations, from the setup of a blank and provision of the required tools<br />

to removal of the part. This NC program has to be complete and error-free.<br />

Achieving this goal requires digitalization and automation before the machine:<br />

i.e., before machining. If all the tasks are prepared in advance in the<br />

virtual world using precise digital twins, there won’t be any surprises during<br />

machining. For example, if the programmer has a precise digital model<br />

of the planned setup situation and the machine and works with digital<br />

twins of the machining tools, including precise geometric data and cutting<br />

data tested in practice, the result is an NC program that already fulfills most<br />

of the above requirements. A subsequent complete simulation in the CAD/<br />

CAM environment provides the final safety element for all traverse movements<br />

and limit switches. This is also ensured by output via a postprocessor<br />

that’s been certified by the CAD/CAM provider. This delivers complete NC<br />

programs with sequences for turning, milling, drilling and even measurement<br />

integrated in the process.<br />

Fast NC programming with automated rules in a knowledge base<br />

Modern automated machining centers have a high part throughput and<br />

therefore require a large volume of NC programs. This means that the NC<br />

programming process needs to be automated, by compiling the company’s<br />

manufacturing knowledge, saving it and making it available in automated<br />

rules in a knowledge base.<br />

hall 9 booth A28<br />

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

no. 3, August <strong>2023</strong><br />


EMO<br />

Adjustable damped boring bar<br />

Long tool overhangs can cause a turning tool to oscillate<br />

when boring internal geometries. In addition<br />

to the resulting chatter marks on the surface, these vibrations<br />

also lead to a significant reduction in tool life.<br />

For unfavourable length/diameter ratios, the experienced<br />

machinist relies on vibration-damping boring<br />

bars, which enable low-vibration machining but which<br />

can still vibrate during certain machining operations.<br />

Paul Horn GmbH has addressed this problem and is presenting<br />

a boring bar at EMO in Hannover that can be adjusted to<br />

the vibration amplitudes that occur. Precise adjustment of the<br />

damping element in the boring bar enables a vibration-free<br />

grooving process. This results in better surface quality without<br />

chatter marks and a significant increase in tool life.<br />

The exact adjustment of the damper, made of a carbide rod<br />

supported in O-rings, is made from the outside via an adjustment<br />

screw. Adjustment is achieved by fine-tuning the pretension<br />

of the O-rings. This allows the boring bar to be precisely<br />

set according to the vibration occurring in each application.<br />

As standard Horn offers the tools from stock in<br />

the length/diameter ratios 5 x 0 and 8 x 0. Higher ratios are<br />

possible as special tools. For the grooving processes, Horn offers<br />

the S224 double-edged grooving system. The Horn cassette<br />

system BK 224 ensures a stable interface between the<br />

boring bar and the inserts. To further increase process reliability,<br />

the boring bars are equipped with an internal coolant<br />

supply.<br />

hall 5, booth A54<br />

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

Customer care special exhibition area and<br />

machine highlights<br />

The UNITED GRINDING Group, one of the<br />

world’s leading manufacturers of grinding, eroding,<br />

laser, and measuring machines as well as machine<br />

tools for additive manufacturing, is considered one of<br />

the pioneers in the development of innovative technologies<br />

in its industry. “Innovate Manufacturing” is<br />

the motto of this year’s EMO Hannover, therefore, the<br />

group cannot be absent.<br />

With its special exhibition area, the group is placing a focus<br />

on Customer Care this year. This includes all products and<br />

services that accompany customers during the service life of<br />

their machines and support them in efficient production –<br />

from “start up” to “retrofit”. Nevertheless, visitors to the trade<br />

show can also obtain comprehensive information about all of<br />

the group’s digital assistance systems. These include the Production<br />

Monitor, the Service Monitor and the Remote Service,<br />

which are grouped under the name UNITED GRINDING<br />

Digital Solutions. In addition, further digital solutions will<br />

be presented at EMO.<br />

Moreover, the public can look forward to several innovations<br />

and highlights among the 16 machines on display:<br />

BLOHM, the specialist for surface and profile grinding machines,<br />

is celebrating a world premiere: the PLANOMAT XT<br />

408 with automatic workpiece loading and unloading as new<br />

solution for internal machining of hydraulic motor stators.<br />

STUDER will also present a novelty: an innovative automation<br />

solution that will be on display on the S31 universal<br />

external cylindrical grinding machine.<br />

And WALTER is presenting for the first time the innovative<br />

“Laser Contour Check” measuring system at EMO, for<br />

highly accurate, non-contact measurement of various tool parameters<br />

on cylindrical tools, which is now also available as<br />

an option for the HELITRONIC MICRO and HELITRONIC<br />

MINI PLUS tool grinding machines.<br />

hall 11, booth E34<br />

further information: www.grinding.ch<br />

56 no. 3, August <strong>2023</strong>

EMO<br />

Mechatronic solutions for metal working<br />

When it comes to international competition,<br />

there ary many challenges for<br />

European manufacturing companies<br />

nowadays. However with the careful use<br />

of digitisation, including artificial intelligence<br />

in combination with robotics and<br />

other automation solutions, it’s possible<br />

to make significant leaps in productivity to guarantee increasingly<br />

stable competitiveness.<br />

This is where the mechatronic solutions developed by HSD come into play.<br />

In fact, EMO will be an unmissable opportunity to get an exclusive preview<br />

of the new ES1020 and ES1040 electrospindle models, developed by HSD to<br />

complement the ES10 Line. The result of technological advancement and<br />

continuous collaboration between our engineering team and our customers,<br />

based on their requirements, these new electrospindle models are able to<br />

adapt to the multiple needs of users and the ever’-increasing pace sought by<br />

today’s market.<br />

In line with the future trends of digitisation and Industry 4.0, HSD will<br />

present a preview of a special “connecting device” which, from now on, can be<br />

installed on the range of electrospindles dedicated to metalworking, allowing<br />

them to be connected to the myHSD IoT platform via a series of sensors.<br />

The connecting device developed by HSD therefore follows the leit motiv<br />

of the event, helping to “innovate manufacturing” and making production<br />

processes more efficient and effective, increasing productivity and quality<br />

while minimising errors and machine downtime.<br />

hall 12, booth A16<br />

further information: www.hsd.it<br />

New standards in the machining of<br />

profile plates and shank tools<br />

Schütte’s 105linear five-axis grinding<br />

machine reduces the setup effort for machining<br />

profile plates and shank tools to<br />

a minimum.<br />

When it comes to grinding cutting tools such<br />

as drills, milling cutters and profile plates,<br />

the proportion of small batch sizes through<br />

to single-part production is increasing. At the<br />

same time demands on shape and dimensional<br />

accuracy and resulting surface qualities<br />

are increasing. In this context, contour tolerances<br />

in the lower micrometer range must be<br />

maintained during grinding, which means<br />

that ideally the first part is also directly a good<br />

part. The bigger the batch size, the more likely<br />

it is that a set-up effort will be tolerated due to an iterative correction of the<br />

grinding result. Especially in the case of single-part production, however,<br />

this setup effort must be reduced to a minimum. The Schütte 105linear offers<br />

the highest first part accuracy, but is also optimally suited for series products<br />

due to its high process reliability.<br />

Highest accuracy with only one measuring process<br />

Also the application area of profile plates deserves special attention. Unlike<br />

cylindrical cutting tools (especially drills/mills/cutting punches), the clamping<br />

of these workpieces is already highly interesting. The nail clamping technique<br />

is a proven, reliable and productive solution for positioning profile inserts<br />

for grinding in the machine and also for machining multi-bladed inserts<br />

over the entire circumference. It is also here important to achieve the<br />

highest accuracies, so the subsequent contact surfaces of the indexable insert<br />

in the toolholder can be measured individually and the grinding contour automatically<br />

adapted to it. This guarantees that in the final use of the workpiece,<br />

no further measurement is required when indexing the insert again –<br />

even for the highest quality demands. The 105linear series is also suited for<br />

this workpiece category because high grinding feeds can be carried out with<br />

the highest precision, which offers an immense productivity advantage.<br />

Simple and fast measurement through automation<br />

Already during process preparation, the machine as well as the robot and the<br />

grinding wheel handling are automatically measured. That’s easier and faster<br />

than manual measurement, and the machine operator can then devote himself<br />

to more important tasks.<br />

hall 6, booth G13<br />

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

no.3, August <strong>2023</strong><br />


fairs in alphabetical order<br />

AMB Stuttgart, Germany<br />

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

bauma Shanghai, China<br />

(November 26-29, 2024)<br />

CMTS Toronto, Canada<br />

(September 25-28, <strong>2023</strong>)<br />

DEBURRING Karlsruhe, Germany<br />

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

EMO Hanover, Germany<br />

(September 18-23, <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 />

METALEX Bangkok, Thailand<br />

(November 22-25, <strong>2023</strong>)<br />

MSV Brno, Czech Republic<br />

(October 10-13, <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 />

SteelFab Sharjah, United Arab<br />

2024 (January 8-11, 2024) Emirates<br />

Stone+tec Nuremberg, Germany<br />

(June 19-22, 2024)<br />

Surface Stuttgart, Germany<br />

Technology (June 4-6, 2024)<br />

TMTS Taichung, Taiwan<br />

(March 27-31, 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 />

2024<br />

2024<br />

<strong>2023</strong><br />

2024<br />

2024<br />

2024<br />

2024<br />

trade fair dates as by middle of August <strong>2023</strong>; we are not responsible for reliability of these dates<br />

58 no.3, August <strong>2023</strong>

impressum<br />

ISSN 2628-5444<br />

publisher<br />

Benno Keller<br />

phone + 49 (0)911 - 2018 200<br />

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

keller@harnisch.com<br />

editor-in-chief<br />

Eric Schäfer<br />

phone +49 (0)911 - 504 98 82<br />

fax +49 (0)911 - 506 38 32<br />

eric.schaefer@harnisch.com<br />

managing editor<br />

Christiane Ebner<br />

phone +49 (0)911 - 2018 260<br />

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

ebner@harnisch.com<br />

publishing company<br />

Dr. Harnisch Publications<br />

management board<br />

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advertising Europe<br />

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copyright © <strong>2023</strong> Dr. Harnisch Publications<br />

AGELTECH GmbH ..................51<br />

Alfred H. Schütte GmbH & CO. KG ....57<br />

ARCH Cutting Tools ................ 20<br />

Balluff GmbH. ......................50<br />


Zerspanungstechnologie GmbH. .....52<br />

Boehlerit GmbH & Co. KG ........... 20<br />

Carl Zeiss AG ...................... 46<br />


Deutschland GmbH ................21<br />

CHIRON Group SE ..................47<br />

DN Solutions Europe GmbH ..........55<br />

EMAG GmbH & Co. KG ..............18<br />

EMO ...............................47<br />

ERASTEEL .........................52<br />

fairXperts GmbH & Co. KG ...........22<br />

FFG European &<br />

American Holdings GmbH ..........51<br />

Fraunhofer Institute for Manufacturing<br />

Engineerig and Automation IPA .....32<br />

Fritz Studer AG .................... 49<br />

Gebrüder Heller<br />

Maschinenfabrik GmbH ......16, 17, 48<br />

GF Machining Solutions ............ 46<br />

Hartmetall-Werkzeugfabrik<br />

Paul Horn GmbH ............... 6, 56<br />

advertising index<br />

company finder<br />

HSD SpA . ..........................57<br />

KAPP GmbH & Co. KG. . .............36<br />

Kern Microtechnik GmbH ........ 40, 53<br />

Lach Diamant Jakob Lach<br />

GmbH & Co. KG ............... 24, 48<br />

LMT Tools GmbH & Co. KG ..........12<br />

MAPAL Fabrik für Präzisionswerkzeuge<br />

Dr. Kress KG ...................13, 18<br />

OERLIKON BALZERS ...............53<br />

OKUMA Deutschland GmbH .........39<br />

Platinum Tooling Technologies, Inc ....19<br />

Rodriguez GmbH .................. 44<br />

Schunk GmbH & Co. KG .............43<br />

Schwäbische<br />

Werkzeugmaschinen GmbH .........49<br />

Spanflug Technologies GmbH. ....... 54<br />

T e b i s<br />

Technische Informationssysteme AG .55<br />

Tyrolit - Schleifmittelwerke Swarovski<br />

AG & Co. K.G. ......................9<br />

UNITED GRINDING Group .........56<br />

URMA AG .........................50<br />

VDW – Verein Deutscher<br />

Werkzeugmaschinenfabriken .... 23, 54<br />

ZECHA Hartmetall-Werkzeugfabrikation<br />

GmbH ............................10<br />


Boehlerit GmbH & Co. KG ...............................................page 13<br />

CERATIZIT Deutschland GmbH .........................................page 5<br />

fairXperts GmbH & Co. KG ..............................................page 39<br />

Fritz Studer AG ............................................... inside front cover<br />

Gebrüder Heller Maschinenfabrik GmbH ..................................page 23<br />

Hartmetall-Werkzeugfabrik Paul Horn GmbH ..........................front cover<br />

Kapp GmbH & Co. KG ..................................................page 15<br />

KELCH GmbH .........................................................page 17<br />

Lach Diamant Jakob Lach GmbH & Co. KG .............................<br />

back cover<br />

Liebherr-Verzahntechnik GmbH AG ......................................page 21<br />

rose plastic AG .........................................................page 19<br />

Supfina Grieshaber GmbH & Co. KG ......................................page 3<br />

VDW .................................................................page 45<br />

WEIMA Maschinenbau GmbH ...........................................page 11<br />

ZECHA Hartmetall-Werkzeugfabrikation GmbH ..........................page 9<br />

no. 3, August <strong>2023</strong><br />


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