hpt 2023 #4

First PCF standard for cemented carbide ■ AI is not an add-on job ■ Giga castings in CNC machining ■ ■ High-performance grade for thread whirling ■ Automation and digitalization in machine tool building

First PCF standard for cemented carbide ■ AI is not an add-on job ■ Giga castings in CNC machining ■
■ High-performance grade for thread whirling ■ Automation and digitalization in machine tool building


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ISSN 2628-5444<br />

high precision tooling<br />

Machine Tools, PCD, PVD, CVD, CBN, Hard Metal <strong>2023</strong> – 4<br />


shows the claws<br />

Deep grinding with »contour profiled« grinding wheels<br />

Diamond and CBN tools since 1922<br />

® ®<br />

®<br />

®<br />

Titelbild hp tooling leo part e fini.indd 1 04.10.23 14:15<br />

■ First PCF standard for cemented carbide ■ AI is not an add-on job ■ Giga castings in CNC machining ■<br />

■ High-performance grade for thread whirling ■ Automation and digitalization in machine tool building ■

cover story<br />

Technical Support.<br />

When You Need it Most.<br />

As engineers, we know our craft and have a thorough understanding<br />

of production processes. If you need us, we are on hand to help with<br />

extensive expertise.<br />

just-our-thing.uk<br />

THE Cutting Tool Solution<br />

CERATIZIT is a high-technology engineering<br />

group specialised in cutting tools and hard<br />

material solutions.<br />

Tooling a Sustainable Future<br />

www.ceratizit.com<br />

U2 no. 4, November <strong>2023</strong>

editorial<br />

Eric Schäfer<br />

editor-in-chief<br />

What is the difference between the pessimist<br />

and the optimist?<br />

None. The pessimist is just better informed, is a joking answer. But this year’s EMO, the world’s leading<br />

trade fair for production technology, proved that a lot of information can also lead to optimism.<br />

Anyone with open ears and eyes could sense a lot of optimism. Understandably so, because the industry<br />

showed its claws at the fair and everything that “constitutes the future of production”, according to<br />

EMO commissioner general Carl Martin Welcker in his summary of the fair. New solutions for<br />

automation, for networking in the factory and for sustainability in production. “When digitalization<br />

meets the factory, the way is clear for new solutions and levels of efficiency. The exhibitors presented<br />

this impressively,” Welcker summed up.<br />

Optimism for the future of the industry could clearly be heard between the lines in the conversations<br />

with the exhibitors, albeit sometimes cautiously expressed. An impression that countered the currently<br />

widespread economic pessimism.<br />

The exhibitors were able to meet the international public’s targeted search for innovations in many<br />

ways. Some of them you can find in this issue of hp tooling. These include numerous new machine tools,<br />

tools and clamping technology that make process solutions simpler, more efficient and more sustainable.<br />

We show you how to better orchestrate large automotive structural components on CNC machines.<br />

We were there when the first Product Carbon Footprint for cemented carbide was presented. This<br />

CO 2 balance provides detailed information on the footprint of indirect emissions caused by tools.<br />

An approach that allows us to look towards the future with optimism.<br />

Eric Schäfer<br />

editor-in-chief<br />

no. 4, November <strong>2023</strong><br />


table of contents<br />

cover story<br />

Tradition. Passion. Innovation: LACH DIAMANT – 100 Years – 7 th part<br />

A spark which ignited a technical revolution – and made Horst Lach the inventor of<br />

spark erosion for the machining of polycrystalline cutting materials 6<br />

materials & tools<br />

CNC diamond wire saws to cut 2D contours in glass 12<br />

The first PCF standard for cemented carbide 14<br />

Update on live tooling 16<br />

New high-performance grade for thread whirling 18<br />

Newly developed diamond and CBN grinding wheels for previously impossible grinding tasks 19<br />

Solutions for Advanced Materials 20<br />

processes<br />

Radically faster tool manufacturing 26<br />

Giga castings in CNC machining 28<br />

Functionally integrated implants through novel synchronized machining processes 30<br />

machining center<br />

HELLER 360 ° solutions at EMO <strong>2023</strong> 32<br />

Flexible machine concept successfully improved 34<br />

New universal loading system 35<br />

Connecting the art of engineering with digital know-how 36<br />

Perform a variety of grinding tasks in quick succession 38<br />

ULTRA technology enables high quality production of small and micro tools 40<br />

Surface quality and removal rate doubled 41<br />

components<br />

Aerotech brings movement to the automation process 44<br />

New standard clamping devices 47<br />

Door opener to hydraulic expansion technology 48<br />

Tool management made easy 49<br />

news & facts 22<br />

fairs 5<br />

impressum & company finder 51<br />

4 no. 4, November <strong>2023</strong>

fairs in alphabetical order<br />

AMB Stuttgart, Germany<br />

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

bauma Shanghai, China<br />

(November 26-29, 2024)<br />

FABTECH Toronto, Canada<br />

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

FEIMEC São Paulo, Brazil<br />

(May 7-11, 2024)<br />

current status<br />

2024<br />

2024<br />

2024<br />

2024<br />

FILTECH Cologne, Germany<br />

(November 12-14, 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 />

hi Tech & Industry Herning,<br />

Denmark<br />

Scandinavia (Sept. 30-Octob. 2, 2025)<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 />

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 />

2024<br />

2024<br />

2025<br />

2024<br />

2025<br />

2024<br />

2024<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 October <strong>2023</strong>; we are not responsible for reliability of these dates<br />

no. 4, November <strong>2023</strong><br />


cover story<br />

LACH DIAMANT – 100 Years<br />

Tradition. Passion. Innovation<br />

part 7:<br />

A spark which ignited a technical revolution –and<br />

made Horst Lach the inventor of spark erosion for<br />

the machining of polycrystalline cutting materials<br />

“When I held my first diamond in my hand in 1908, I would not<br />

have imagined that one day diamonds would not only be used in the<br />

automobile industry but also for the machining of wood and plastics”.<br />

Jakob Lach, the company founder, said this on camera in 1980.<br />

It would become the preface for the first presentation of a new technique<br />

for machining wood and plastics – using diamonds as cutting<br />

material – the Dia Tool. This video, with audio translated into<br />

multiple languages, has lost none of its relevance for the choice of<br />

appropriate tools within the furniture, flooring and composite industries;<br />

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

Company founder Jakob Lach, 1894-1984<br />

(photo taken in 1980)<br />

Continuing with the 100-year history of LACH DIAMANT®, today I will<br />

take you to the year of 1977. Just for orientation:<br />

46 years ago, Steve Jobs and Stephan Wozniak launched Apple II, the first<br />

PC on the market; William Gates and Paul Allen founded the company<br />

Microsoft, and Voyager 1 and 2 started their journey to Jupiter.<br />

What was happening at LACH DIAMANT?<br />

The pioneer and development activities regarding<br />

polycrystalline (PCD) cutting tools<br />

(since 1973), and now PCBn for turning of<br />

weld-on alloys (as in part 6 “The dawn of CBN<br />

hard turning – turning instead of grinding”)<br />

now show their own success dynamics.<br />

Users and trade press alike were full of<br />

praise. And as if this was not enough, the success<br />

reports we received every day also stimulated<br />

the success of other products from<br />

LACH DIAMANT®. For example, diamond<br />

First time 1977: tool for the cutting of circuit boards<br />

6 no.4, November <strong>2023</strong>

cover story<br />

First introduced in 1971:<br />

LACH diamond and CBN tressex® grinding wheels for<br />

deep grinding of HSS with polyamide bond<br />

Hanover fair in 1974: demonstration of the first polycrystalline<br />

diamond end milling cutter dreborid® for cutting fiberglass<br />

materials, first introduced at the Hanover Spring fair<br />

and CBN Borazon® grinding wheels, such as the newly developed<br />

polyamide bond tressex® for deep grinding of carbide<br />

and HSS (slogan: “tressex® shows its claws”) or the “two-inone”<br />

for rough and finish grinding with only one diamond<br />

grinding wheel.<br />

For the dressing of conventional grinding wheels, so-called<br />

drebodress® dressers were developed, based on synthetic<br />

diamonds. In the meantime polycrystalline dreborid®<br />

diamond inserts also passed their baptism of fire with flying<br />

colours during the milling of fiberglass and carbon fiber materials<br />

as well as graphite.<br />

In 1977 a separate product catalogue for “Milling – Cutting<br />

– Drilling and Edge Processing” of composite materials<br />

was created, featuring the now so-called dreborid® K-PCD<br />

tools. The front page was green. Green like most “GRP” fiberglass<br />

materials.<br />

“Was there something else… ?”<br />

…I thought at that time, and I remembered the invitation<br />

to a tradeshow named “productronica” which was scheduled<br />

to take place in Munich, November 1977, for the second<br />

time. Below, I am quoting from my article series “Poly, poly<br />

or what?” (article number 4 in 2020 How a trade show initiated<br />

a brilliant idea…). This announcement of a tradeshow,<br />

unknown to me until then, did, in retrospect, prove to be a<br />

turning point for the recognition of polycrystalline diamond<br />

tools. productronica in Munich 1977 was advertized as a component<br />

fair for the electronic and circuit board industry.<br />

I was interested. Circuit boards? The base material is fiberglass<br />

reinforced plastic (GRP), which was familiar to us. We<br />

successfully cut this with PCD, and dust-free at that.<br />

In order to show this at a fair successfully, we needed a<br />

demonstration machine. We found it at the former AEG in<br />

At productronica 1977, LACH DIAMANT® demonstrated for the first time PCD tools for cutting circuit boards<br />

no. 4, November <strong>2023</strong><br />


cover story<br />

And then, it sparked<br />

The turning point of this initially negative<br />

story came one year later, October 1978, as an<br />

advertizement for a spark eroding machine<br />

of the Frankfurt-based company MATRA.<br />

Never heard of such a thing. Spark machine?<br />

But then I remembered the words of my father,<br />

who mentioned several times that electricity<br />

always is a factor when grinding natural<br />

diamonds on obligatory cast wheels.<br />

“What the heck?” I said to Gerhard Mai, our<br />

newly appointed master of PCD production,<br />

a former cutter of natural diamonds, trained<br />

at LACH DIAMANT®. “Let’s take a look<br />

at this…”<br />

Wire machine, type EDM 1979/80, during the processing of<br />

polycrystalline cutting materials (re-enacted photo with Dirk Rüttgers)<br />

Seligenstadt: a Swiss machine, manufactured by Amacher. Three processes<br />

could be executed on this small precision mini machine of the HAMBA type:<br />

cutting, scoring and edge processing. Excellent. Registered for the fair. Internal<br />

work order for the three needed PCD tools or saws, respectively. Only<br />

the production had some concerns: “How are we supposed to sharpen these<br />

rotating tools? It will take forever….” In fact, for twelve teeth, for example,<br />

we needed 35 hours of grinding time! But I thought, and said it as well: “You<br />

will manage, so far, you have always come through with an idea.”<br />

At first, productronica 1977 was a great success for LACH DIAMANT®.<br />

Due to an increased demand for electronic circuit boards, visitors from the<br />

great and famous companies gathered around the little Amacher machine to<br />

admire this precise, selective and dust-free cutting of PCB, the base mate rial<br />

for circuit boards.<br />

To this day I remember the gentlemen from Siemens and NCR who immediately<br />

thought of diamond saws with a diameter of 300 to 350 mm for machining<br />

packages, and spontaneously ordered samples for further testing.<br />

It could have been so nice. Even in 1977 cutting circuit boards could have<br />

been more efficient. If…, yes , if the following had not happened: “Boss, we<br />

are really doing everything for you, but we can only focus on either producing<br />

scorers and saws for circuit boards, or we can continue to serve customers<br />

like Bosch and Kautt & Bux with commutator diamonds.” For then that<br />

was it, regarding the rotating PCD tools. “Grinding” technology with a result<br />

of 35 hours for 12 teeth made its point very clearly. During the following<br />

12 months I had more than one unpleasant task. Engineers and industry<br />

experts, “hot” for this successfully introduced new technology, overwhelmed<br />

me with questions, and accused me of holding back this technology<br />

for whatever reason. In short: they were miffed.<br />

Whereas the only culprit was this beastly polycrystalline synthetic diamond<br />

material; even experienced cutters of natural diamonds surrendered<br />

to it. Over and over we were pondering how we could conquer this invincible<br />

stuff better, meaning faster.<br />

Quickly we had made an appointment with<br />

Mr. Schreiber and Mr. Becker of MATRA.<br />

“Yes, stop by with your extremely-hard-togrind<br />

carbide, we will see what we can do…”<br />

We prudently had failed to mention that this<br />

carbide was in fact PCD.<br />

I clearly recall how Mr. Becker greeted us at<br />

the entrance and lead us into a hall with rail<br />

access. Left and right from the entrance were<br />

some, for me at that time, unidentifiable machines.<br />

We stood in front of a machine that I<br />

would describe as some sort of “sinking machine”.<br />

The PCD sample we handed over for<br />

the “spark test” was carefully mounted and<br />

disappeared in a “brew” which I now understand<br />

as a kind of dielectric fluid. The power<br />

was switched on. I could tell from the look on<br />

Mr. Becker’s face that he expected our PCD<br />

to show a reaction. We took turns to examine<br />

the probe under a magnifying glass to<br />

see whether anything was changing. Nothing<br />

happened, not even for the next five minutes.<br />

“Well, I am sorry, apparently nothing works<br />

with this carbide…” they said regretfully.<br />

“Well then, it was worth a try,” we thanked<br />

them and were already on our way out of<br />

the hall, when I discovered a machine in the<br />

far right corner. It looked slightly different,<br />

mainly because of an additional “tower- like”<br />

structure. “What kind of machine is this,” I<br />

heard myself asking, “a wire machine, it’s a<br />

similar machine,” was the answer, “alright,<br />

since you are already here and if you want to<br />

we can try another experiment. Let’s go over<br />

there, but I have to tell you right away that it<br />

contains a profile for one of our customers.” I<br />

only said “that doesn’t matter.” So the sample<br />

was mounted again – it immediately started<br />

to brew – and it worked right away, in the truest<br />

sense of the word. The hot wire actually<br />

cut the described profile out of the PCD – and<br />

formed it. This visible success surpassed all<br />

8 no. 4, November <strong>2023</strong>

cover story<br />

of our expectations. This “beastly material” had finally been<br />

conquered for the first time.<br />

A technical sensation<br />

While I am writing this, 45 years later, I am asking myself<br />

what did we think at that moment. Were we actually aware of<br />

the ramifications of this discovery?<br />

Today I interrupted Gerhard Mai, now retired, with this<br />

question for a few long minutes. Of course we had witnessed<br />

how the force of spark erosion had profiled a small piece, in<br />

a bubbling brew, of polycrystalline diamond (PCD) cutting<br />

material, i.e., it was processed. Without extensive grinding – if<br />

the latter would have been possible at all. Were we thinking<br />

of the saws and milling tools, produced for the productronica<br />

one year ago (in 1977), with an enormous expenditure of 35<br />

hours of grinding time? Or did we even consider the possibility<br />

that our suppliers, General Electric or DeBeers (status of<br />

1978), could (not only) provide us with elaborately produced<br />

60 ° or 90 ° segments but instead with PCD blanks, so that we<br />

could wire-cut the desired segments ourselves? Did we anticipate<br />

the production of shaft angle PCD tools such as milling<br />

tools, saws etc? Mr. Mai and I agreed: no, we had not thought<br />

of any of this.<br />

I was then driven by the idea to immediately register this<br />

discovery or this process for a patent; we did this on the<br />

same day, on October 13 th , 1978, with our patent attorney<br />

Dr. Strasse (✝) in Hanau. Today Dr. Stoffregen, who later took<br />

over the law firm, still remembers this day very clearly.<br />

For the 100-year anniversary of LACH DIAMANT® he<br />

wrote (in extracts): “Look into the patent register, you can<br />

find more than 100 patent rights registered for your company<br />

within the last 50 years, and almost half of them name Horst<br />

Lach as the inventor. One of them I want to particularly<br />

single out today since it also has an anniversary. As a young,<br />

newly licensed patent attorney, I was charged with the task<br />

to draft the paperwork for an invention of young Mr. Horst<br />

Lach; it had to do with processing polycrystalline diamonds,<br />

a beastly, difficult-to-work with material as he put it. The first<br />

patent application for your invention was filed at the German<br />

patent office on October 13 th , 1978, exactly 45 years ago,<br />

and registered at the European patent office exactly one year<br />

later, on October 13 th , 1979. The publication reference number<br />

is 0010276. This low number indicates that you were one<br />

of the earliest registrants at the European patent office. The<br />

main claim of this patent is worded as follows: procedure for<br />

electro erosive processing of polycrystalline synthetic diamonds,<br />

characterized by the use of spark erosion for the production<br />

of user-defined profiles. This short description indicates<br />

that this patent has an extensive scope of protection.<br />

The patent claim ensures a simple way to process the beastly<br />

PCD material, a revolutionary invention, first for tool manufacturers<br />

in the wood and composite industries, but later<br />

was deployed wherever rotating tools are used, such as in the<br />

automobile and aircraft industries.”<br />

A conversation with Wumm<br />

Our team, Dipl.-Ing. G. Hobohm, Mai and Wagner, all sworn<br />

to utmost confidentiality, had not been able to think about<br />

The unleashed spark for cutting polycrystalline diamond<br />

and CBN materials<br />

how to proceed from here, when an unexpected phone call<br />

suddenly took the initiative away from us. The caller was Mr.<br />

Denker, now with Resopal in Grossumstadt (former Römmler<br />

GmbH). He immediately came to the point. “Mr. Lach, I read<br />

that you introduced diamond milling tools at a tradeshow (he<br />

meant productronica 1977 in Munich)”. I confirmed this. Mr.<br />

Denker continued: “We currently have a problem; can you<br />

build a profile milling cutter for us?” In an instant I was wide<br />

awake. Only 14 days ago I would have answered with a “no, I<br />

am afraid not”, but now? Most likely, I answered with a longdrawn<br />

“yes!” and so Mr. Denker proceeded: “what we call<br />

an American milling cutter, with a profile for a postforming<br />

worktop with a cutting width of 45 mm, and a tool diameter<br />

of 160 mm”. When the dimensions were mentioned, I<br />

responded with “BUT – at the moment we are not yet ready<br />

for this size in our production.” Denker: “that does not matter;<br />

we will send you two Leuco milling cutters with carbide<br />

cutting edges, and you simply un-braze them and put your<br />

diamonds on top.”<br />

That is how the short conversation run, but yet it was pivotal<br />

for the future of this cutting material, now still in its fledgling<br />

stages. For all of us, tool manufacturers, users, and for<br />

the producer General Electric.<br />

Under Pressure<br />

The management of GE Superabrasives in Worthington/Ohio,<br />

ranging under the department “Filament Lamps” in the<br />

no. 4, November <strong>2023</strong><br />


cover story<br />

be profitable at that time. The number of items<br />

sold were too low.<br />

The general manager of GE Superabrasives,<br />

Louis Kapernaros, who would become a good<br />

friend of mine in later years, talked very<br />

openly with me about this. For at least another<br />

seven years after the first market launch<br />

(1973), it was a laborious process to cut the<br />

PCD cutting edges out of pressed PCD blanks<br />

with electroplated cutting wheels. As I remember,<br />

the length of the available cutting<br />

edges was 6.6 mm and was increased to only<br />

13.2 mm in the following months – thanks to<br />

new presses.<br />

Due to a lack of efficient technologies for<br />

processing/forming this superior cutting material<br />

(compared to carbide), marketing of<br />

PCD tools remained limited to single-tipped<br />

turning tools and inserts; this was simply too<br />

little to generate higher sales and production<br />

numbers in order to gain greater acceptance<br />

within the cutting industry.<br />

1979/80: worldwide first manufactured PCD diamond milling cutter for<br />

profiling plastic-coated chipboards for use in wood/plastic processing machines,<br />

double-end profiler, with up to 350 times better durability<br />

company’s hierarchy, came under a lot of pressure at that time; despite off all<br />

efforts and investments, GE Superabrasives had not yet managed to produce<br />

the same profit margins as a simple “pin” manufacturer.<br />

In short, the pressure was so great that the “Filament Lamp” department<br />

threatened to part with the subdivision “Superabrasives”. I understood why<br />

sales of polycrystalline inserts (PCD) under the GE “compax” label could not<br />

Furthermore, GE Superabrasives was in<br />

direct internal competition with GE subsidiary<br />

“Carboloy”, a carbide manufacturer with<br />

most likely little interest in polycrystalline<br />

diamond cutting materials.<br />

A sudden turning point in sight<br />

This phone call and quasi the first order for<br />

the production of two PCD with 45 mm cutting<br />

width should revolutionize the mass production<br />

of entire industries. Starting with the<br />

wood and plastics processing industry (for<br />

example the resopal factory), and followed by<br />

automobile, aircraft, and wind energy industries<br />

as the now leading processing industries<br />

for aluminum, fiberglass and carbon fiber reinforced<br />

materials and plastics.<br />

The appropriate and superior tools of the<br />

trade were now discovered and available – the<br />

spark erosion!<br />

More history and interesting stories will follow in the next edition of the<br />

100-year anniversary series of LACH DIAMANT®<br />

By the way, the first delivered PCD milling<br />

cutters were six (!) months in use during<br />

3-shift operation. Directly comparable carbide<br />

tools had to be uninstalled and sharpened<br />

by an expert technician after every shift.<br />

From the beginning on the PCD milling<br />

cutters had 350 times more durability than<br />

previously used carbide tools. Since it was<br />

possible to resharpen the PCD milling cutter<br />

as well, it could be used for approximately<br />

three to four years.<br />

Yours, Horst Lach<br />

further information: www.lach-diamond.com<br />

10 no.4, November <strong>2023</strong>

materials & tools<br />

“AI is not an add-on job”<br />

At EMO <strong>2023</strong><br />

precision tool manufacturers<br />

showed how<br />

machines, systems or<br />

components can be<br />

cleverly equipped with<br />

AI in the future.<br />

Research at the<br />

Fraunhofer Institute for<br />

Production Technology<br />

IPT in Aachen, Germany,<br />

proves that AI can advance<br />

machining. The<br />

Dr.-Ing. Maik Frye<br />

researchers were able to<br />

demonstrate, for example,<br />

the potential for users to reduce the measurement effort<br />

required in milling processes by up to 50 % thanks to the<br />

use of AI. This increases value creation immensely. When<br />

it comes to introducing AI in manufacturing companies,<br />

Dr.-Ing. Maik Frye, group leader for production quality at<br />

the Fraunhofer IPT, sees three hurdles that need to be overcome,<br />

according to him. “The biggest hurdle, at least currently,<br />

is people. Many don’t trust the models and are afraid<br />

that data could fall into the wrong hands or are reticent to<br />

engage with the new technology.” In addition the adoption<br />

of AI depends on the data base. “Most of the time the<br />

necessary data is not available in the required quality,” says<br />

Frye, who helps companies implement AI. “In many cases<br />

companies have to generate the appropriate database first<br />

on the way to implementation.” The third hurdle: “AI is not<br />

an add-on job,” Frye points out. Companies should create<br />

their own staff capacities for this in order to be able to<br />

accompany the process in a promising manner.<br />

Using AI to tackle the shortage of skilled workers<br />

Aware of the need for additional resources, the Paul Horn<br />

carbide tool factory in Tübingen started the introduction of<br />

AI from the very beginning. “We have created directly capacities,<br />

whose focus is on AI,” says Markus Kannwischer,<br />

head of technology and member of the management team<br />

at Paul Horn. Currently various systems, such as for grinding,<br />

are being tested. In the in-house milling shop, on the<br />

other hand, AI is currently already being implemented. The<br />

goal is to increase process reliability and to fully utilize the<br />

cutting tools until the end of their service life. According<br />

to Christian Stark, development engineer at Paul Horn,<br />

employees will also appreciate AI in the future. “AI will<br />

help them to better understand the complex interaction of<br />

processes and receive recommendations for process optimization,”<br />

Christian Stark looks into the future. “This is a<br />

big plus in times of shortage of skilled workers, as we can<br />

optimize setup times and help new employees make the<br />

best possible decision faster.” This brings the big goal of<br />

equipping the entire group’s machines with AI within<br />

reach.<br />

AI-capable sensory clamping technology<br />

The sensory clamping technology of the ROEMHELD Group<br />

from Laubach is already AI-capable today: this is because the<br />

sensors provide all data in the correct format and enable the<br />

overall system to intervene in the process and, if necessary, adjust<br />

machining parameters. “We are still at the beginning in<br />

terms of the possible applications of AI,” says Philipp Ehrhardt,<br />

managing director of Römheld GmbH, Friedrichshütte. According<br />

to him the potential is huge, especially with a view to<br />

automated, autonomous manufacturing. Visitors of EMO <strong>2023</strong><br />

could find out how intelligent the solutions from the Laubachbased<br />

company already are, by taking a look at a demonstrator.<br />

Various clamping elements equipped with extensive sensor<br />

technology for Industry 4.0 applications were there in use. The<br />

STARK.intelligence sensor system is one of them. It records<br />

the entire process sequence, keeps an eye on maintenance<br />

and allows end-to-end digitization and communication of all<br />

clamping devices. The zero-point clamping systems connected<br />

to this solution measure paths, positions, temperatures and<br />

pressures in real time and provide information about the “state<br />

of health” of the clamping devices. The sensor system can also<br />

be successfully equipped with AI. Ehrhardt is certain, “It’s just<br />

a matter of time before AI becomes a no-brainer.”<br />

TRUST IN<br />


further information: www.vdma.org<br />

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materials & tools<br />

CNC diamond wire saws<br />

to cut 2D contours in glass<br />

The German electrical discharge machine supplier<br />

Ageltech GmbH has also a series of CNC diamond wire<br />

saws in its range, the MK series, and focuses on an outstandingly<br />

attractive price-performance ratio.<br />

The technology has a wide range of applications, the gen eral<br />

rule is: “Diamond wire cuts everything”. CNC also enables the<br />

creation of contours and 2D free forms, of course also simple<br />

straight cuts such as for samples or discs, e.g. for R&D or<br />

quality verification. Wire generally allows a minimal cutting<br />

gap, for example around 0.2 - 0.5 mm. The possible uses are<br />

very extensive and include most non-conductive materials,<br />

e.g. glass, ceramics, crystals, CFRP, stone, sandwich materials,<br />

composites or even highly porous AM materials and<br />

honeycombs. In terms of shape the possibilities range from<br />

simple disks and cuboids or cylinders to more sophisticated<br />

shapes such as special seals or undulated contours to complex<br />

structures such as name lines or logos.<br />

The saws are suitable for the production of discs, cuboids,<br />

cylinders, ornaments, repair parts and also for the economical<br />

separation of the 3D print pieces from the building<br />

boards. Due to the simple medium of diamond wire, which is<br />

operated with filtered city water and an additive, only low operating<br />

costs are incurred. There is the possibility of test work<br />

in advance on the specific workpiece or the ordering of service<br />

contract works.<br />

Experience in practice<br />

The possible uses are very extensive, because diamond is the<br />

hardest element and therefore cuts everything except tough<br />

and ductile materials that clog the wire. Due to the competition<br />

with EDM saws, diamond wire is more recommended<br />

for non-conductive materials. Compared to the band and<br />

disc saw blade, the wire can score points with its smaller kerfloss<br />

and even sawing performance in all directions around<br />

360 °, which, however, is also associated with a significantly<br />

lower cutting performance. The 360 °-capable cutting is made<br />

possible by a CNC control of the X and Y axes, which move<br />

the tool table in increments of 1 µm. A more precise infeed<br />

does not make sense, because even with the minimum wire<br />

cutting height of 200 mm of the smallest saw MK200, there is<br />

a wire deflection in the range of well over 1 micron, especially<br />

with 2D movements.<br />

MK200 CNC diamond wire saw<br />

Simple sawing of straight lines for samples<br />

The MK series ranges from the MK200 model with machining<br />

options for workpieces of 385 x 495 x 200 (h) mm³<br />

and cutting lengths of 200 x 250 mm in several increments<br />

to the MK500 model for large workpieces of<br />

650 x 1000 x 600 (h) mm³ and cutting lengths of 500 x 630 mm.<br />

All machines are designed for industrial use and dimensioned<br />

accordingly. The cutting line can be created, for<br />

Complex 2D contour cut with MK200<br />

12 no. 4, November <strong>2023</strong>

materials & tools<br />

example, simply by transferring a DXF file from AutoCAD® and correcting<br />

it by entering an offset – by reason half the wire thickness. With this<br />

the outer edge of the wire runs along the outer edge of the workpiece of<br />

the drawing. The course of the cut can be followed on the monitor, the<br />

elapsed cutting time and the expected remaining time as well as other<br />

helpful parameters are displayed.<br />

The technology is tried and tested and uses diamond wire as the cutting<br />

medium, which has matured and is inexpensive after decades of development,<br />

resulting in low operating costs from 2 - 3 Euro/hour which originate<br />

from: wire, water and an additive for cooling, anti-oxidation, lubrication<br />

and particle as the cheap consumables, and 4 wire guide rollers and<br />

an occasional exchange of ball bearings define the usual, also cheap wearing<br />

parts. A significant reduction in unit costs can often be achieved using<br />

batch processing by assembling several workpieces together (stacking).<br />

A wide range of fixing options and a rotation unit for faster sawing<br />

of discs or for surface improvement, as well as a suitable range of diamond<br />

wires and consumables and spare parts complete the offer. Finally,<br />

the specially developed CNC system offers a number of advantages:<br />

on the one hand, it enables quick reactions such as update options for<br />

new requirements, on the other hand it is Linux-based and thus also<br />

reduces the risk of viruses. For different safety standards the MK series<br />

can be equipped with various protective housings and automatic switchoffs,<br />

right through to a laser beam cage. Basic users can learn how to<br />

operate and set up the machines quickly. Ageltech offers own service<br />

for Germany, Austria and Switzerland, as well as for most of the rest of<br />

Europe.<br />

Your<br />

Automation<br />

Partner<br />

When Precision Motion<br />

Control Matters<br />

Outstanding price-performance ratio<br />

According to Europe sales manager Alexander Postl, Ageltech deliberately<br />

focuses on an outstandingly attractive price-performance ratio. In<br />

terms of price, international sourcing contributes to the lowest purchasing<br />

costs. Purchasing large quantities in a network and streamlining the acquisition<br />

processes contribute to further cost reduction. The CNC system<br />

is based on a specially developed solution. And this is where the quality<br />

side is reached: Ageltech checks and revises weak points in each individual<br />

machine and assembles all other components in Germany according to<br />

German standards. There is a 100 % initial quality control.<br />

Having its own R&D team in the group enables quick reactions to customer<br />

requests and continuous development of the CNC diamond wire<br />

saws. The last point is the free best advice principle, which means selection<br />

according to the customer’s requirements and thus helps to avoid unnecessary<br />

and overpriced machines and options. On request, the customer<br />

receives a customized production process together with his saw, including<br />

the transfer of know-how. This is particularly valued by market participants<br />

from outside the industry who are building up another field by<br />

expanding their range of products and services.<br />

Conclusion<br />

Ageltech’s CNC diamond wire saws are robust machines with a sensitive<br />

tool and offer an outstanding price-performance ratio thanks to<br />

optimized purchasing structures, own CNC system and German revision,<br />

assembly and quality control. With the CNC diamond wire saws of the<br />

MK series, laboratories and institutes can carry out their R&D tasks such<br />

as probes and samples, as well as manufacturing companies can produce<br />

their prototypes and small series and the industry can also produce their<br />

large series.<br />

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



materials & tools<br />

The first PCF standard for cemented carbide<br />

On the occasion of EMO <strong>2023</strong> in Hanover,<br />

CERATIZIT has kicked off the introduction of the first<br />

Product Carbon Footprint standard (PCF) for carbide<br />

products. Since September 18 the PCF classification of<br />

the first wave of products is displayed in the shop and<br />

on all invoices. Detailed information on the PCF of the<br />

corresponding products can be requested as an additional<br />

service.<br />

“The start of the systematic introduction of PCF figures in<br />

our product portfolio is an important milestone. Not only<br />

do they allow our customers to calculate their own corporate<br />

carbon footprint more accurately. The PCF figures also<br />

provide the basis for setting up a strategy to reduce their own<br />

emissions,” executive board spokesman Dr. Andreas Lackner<br />

commented on the launch of CERATIZIT’s PCF offering.<br />

Different service levels<br />

CERATIZIT’s service offer around the PCF includes several<br />

service levels. For all products already included in the<br />

range of services, the PCF class is displayed in the shop and<br />

on the invoice at no extra charge. This alphabetical classification<br />

with six classes from A to F allows to know and assess<br />

a product’s footprint with a single glance. The second option<br />

includes an average PCF value in kg CO 2 e/kg product as well<br />

as a summary overview of the total carbon footprint related<br />

to the listed products and volume manufactured and supplied<br />

in a customer-defined time period. The most comprehensive<br />

service level provides customers with detailed PCF information<br />

on every purchased product for which the data is available.<br />

At the start this information will be offered only for certain<br />

products. But the goal is to gradually expand the share<br />

and ultimately provide PCF information for all products.<br />

upGRADE products always come with<br />

PCF information<br />

Products from the upGRADE family, which are made from<br />

100 % secondary raw materials and have a particularly low<br />

PCF, also take on a special position. With these products, detailed<br />

PCF information is already included in the purchase<br />

price. The CT-GS20Y grade for rods for cutting tools and<br />

the KLC20+ grade for wood working are made from strictly<br />

selected secondary raw materials and combine premium<br />

performance with a particularly low PCF, which is on average<br />

around 60 % below the PCF of corresponding standard<br />

CERATIZIT grades and places them in PCF class “A”.<br />

Externally verified calculation model<br />

The calculation approach is in line with the ISO 14067:2018<br />

standard and has been critically reviewed by a third party,<br />

denkstatt, a member of Inogen – Environmental Alliance<br />

(https://denkstatt.eu/).<br />

In-depth information about the PCF model<br />

on request<br />

Detailed information on the model behind the Product Carbon<br />

Footprint calculation will be available in the coming<br />

weeks but can already be requested via the link on the landing<br />

page (https://www.ceratizit.com/int/en/sustainability/pcfclassification.html)<br />

and directly by email to sustainability@<br />

ceratizit.com. Customers, partners and market companions<br />

and all others are all invited to take a look at the model and<br />

adopt it if they wish. Only by working together will it be possible<br />

to lead the hard metal industry into a more sustainable<br />

future.<br />

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

14 no. 4, November <strong>2023</strong>

materials & tools<br />

Ultra-hard premium cutting materials for Europe<br />

The South Korean company ADICO produces and distributes<br />

PCD (polycrystalline diamond) and PcBN (polycrystalline cubic boron<br />

nitride) high-performance cutting materials in application-specific<br />

grades, that serve as the starting material for the production<br />

of high-quality cutting edges and tools. They are used worldwide in<br />

demanding machining applications, including in the automotive,<br />

aerospace and woodworking industries.<br />

In order to better serve these customers in Europe, ADICO is expanding its<br />

European sales activities. Philipp Homann, an experienced sales expert, has<br />

taken over the management of European sales as sales director Europe. He<br />

has more than 20 years of experience in international sales of PCD and PcBN<br />

cutting materials.<br />

ADICO was founded in 1999 by the two developers Dr. Hyun Sam Cho<br />

and Kyoungryoul Han as an independent manufacturer of ultra-hard cutting<br />

materials for the industrial location of South Korea. The company gradually<br />

established itself internationally and has made a name for itself as a premium<br />

supplier of PCD and PcBN. Today its customers include well-known international<br />

tool manufacturers for the metal- and wood-cutting industry. The<br />

strengths of the South Korean cutting material supplier lie above all in the<br />

high quality, the production within the lowest tolerances and the application-specific<br />

cutting material development.<br />

Exterior view of the ADICO company<br />

“We develop the perfectly adapted cutting<br />

material made of PCD or PcBN specifically<br />

for our customers’ applications,” emphasises<br />

Philipp Homann. All customers in Europe<br />

can now increasingly benefit from this.<br />

further information: www.adico.kr<br />

New end mills for volume machining of<br />

aluminum materials<br />

The alu-cut “Aerospace” WF series from FRANKEN represents<br />

an end mill family made of carbide and HSSE-PM for volume<br />

machining in aluminum materials. The alu-cut “Base” product line<br />

is supplemented by new diameters and lengths.<br />

The new high-performance tools of the alu-cut “Aerospace” WF range were<br />

specifically developed for the process-reliable volume machining of aluminum<br />

and copper alloys in the aerospace industry. The uncoated version is designed<br />

to machine wrought and cast aluminum alloys with a silicon content<br />

of up to 7 %. There are also GLT-coated versions available for cast aluminum<br />

alloys with a silicon content of up to 12 % and copper alloys.<br />

A newly developed geometry of the chip divider enables low-vibration<br />

roughing and finishing of aluminum. The WF cutting edge geometry for<br />

aluminum machining is available with and without corner radius, as well<br />

as in two length versions. The end mills have an internal coolant-lubricant<br />

supply with radial and axial outlet (ICRA).<br />

New lengths and diameters for alu-cut base<br />

The alu-cut “Base” product range includes high-performance end mills with<br />

different geometries for universal use in aluminum and copper alloys. Volume<br />

machining in aluminum can be carried out with all available variants<br />

– depending on the machine stability. In addition these tools with finishing<br />

teeth can achieve dimensionally accurate and high quality surfaces<br />

without losing flexibility. The end mills are fitted with a chamfer, the product<br />

line is supplemented by different variants with corner radius so as to always<br />

The alu-cut “Aerospace” WF end mills from<br />

FRANKEN are specialist tools for volume<br />

machining of aluminum and are designed<br />

for use in the aerospace industry<br />

have the suitable tool available for the specific<br />

requirements on the component. The existing<br />

geometries are supplemented by the diameters<br />

14 and 18 mm. Additionally there are two new<br />

lengths: 3.5 x D and 6 x D.<br />

further information: www.emuge-franken.com<br />

no.4, November <strong>2023</strong><br />


materials & tools<br />

Update on live tooling<br />

A review of this machining method, the basic concepts and<br />

some exciting developments in the technology<br />

written by Preben Hansen, president Platinum Tooling Technologies Inc., Prospect Heights, Illinois, USA<br />

Live tooling, as a component on a lathe, is specifically<br />

manipulated by the CNC to perform various<br />

milling, drilling and other operations while the workpiece<br />

is being held in position by the main or sub spindle.<br />

These components, whether BMT or VDI, are also<br />

called driven tools, as opposed to static tools, that are<br />

used during turning operations. All live and static<br />

tools are built per the machine tool builder’s specification<br />

for each of the various models they produce. A<br />

key to running a successful job shop or production department<br />

is to partner with a supplier who can meet<br />

the tooling needs for all or most of the machines on<br />

your floor.<br />

Most often, live tooling is offered in standard straight and 90 °<br />

angle head configurations with a wide range of tool output<br />

clamping systems, including ER collet chuck, arbor, Weldon,<br />

Capto, whistle notch, hydraulic, HSK, CAT, ABS and a variety<br />

of custom or proprietary systems developed by the many<br />

suppliers to the industry.<br />

When the need arises for a new machine tool, careful consideration<br />

should be made to determine which live tools<br />

are appropriate for your application. While a standard machine<br />

tool package will help you get started, it is important<br />

to anticipate job and volume changes, as well any unforeseen<br />

A typical ER collet adapter changing system allows<br />

for greater flexibility and cost savings<br />

machining challenges from the beginning, in order to avoid<br />

machine downtime. This short article is meant to give you a<br />

set of parameters to consider when evaluating the live and<br />

static tooling to use in your shop or production department.<br />

Simply stated, you need to do as much evaluation of your process,<br />

when determining the proper tooling to be used, as you<br />

did when you evaluated the various machines available for<br />

purchase. This fact is often overlooked and that can be a critical<br />

error, in the long run.<br />

Your examination can range from the simple (external vs.<br />

internal coolant, for example) to the sublime (adjustable or<br />

multi-spindle configurations) to the custom tool, that may be<br />

required and built to suit your special application. Finding a<br />

supplier who has an in-house machine shop for the preparation<br />

of special tools is a great value-add.<br />

The combination of taper roller bearings and spindle bearings<br />

are best for live tool rigidity<br />

Tool life is the product of cutting intensity, materials processed,<br />

machine stability and, of course, piece parts produced.<br />

Two seemingly identical job shops can have vastly<br />

different tooling needs because one is automotive and one<br />

is medical, or one specializes in the one-off and low-volume<br />

work, while the other has a greater occurrence of longer running<br />

jobs. The totality of your operation determines the best<br />

tooling for the machines being purchased.<br />

16 no. 4, November <strong>2023</strong>

materials & tools<br />

Bearing construction and the resulting spindle concentricity<br />

drive the life of any tool. You might find that just a 10 - 15 %<br />

greater investment in a better design can yield both longer<br />

lasting cutters and consistently superior finish on your products.<br />

Of course the stability and rigidity of the machine tool<br />

are always critical factors. Bevel and spur gears that are hardened,<br />

ground and lapped in sets are best for smooth transition<br />

and maximum torque output. Taper roller bearings are<br />

consistently superior to spindle bearings in live tool milling<br />

applications, so look for a combination system to get the<br />

highest rigidity possible. Also look for an internal vs. external<br />

collet nut, so the cutting tool seats more deeply in the tool,<br />

as superior performance will result.<br />

Likewise, high pressure internal coolant might be desirable.<br />

Look for 2000 psi capabilities in 90 ° tools and 1000 psi<br />

in straight tools.<br />

You need to ask another question, namely, is the turret<br />

RPM sufficient to handle the work to be done? It’s possible<br />

that a live tool with a built-in speed increaser, often called a<br />

speed multiplier, would be helpful. Would it be beneficial to<br />

move secondary operations to your lathe? Gear hobbing can<br />

be accomplished in this manner, as can producing squares or<br />

flats, through the use of polygon machining.<br />

Standard live tooling most often is best suited to production<br />

work, where the finish, tolerances and cutter life are critical,<br />

while quick-change systems may be better suited to the<br />

shop producing families of products and other applications<br />

where the tool presetting offline is a key factor in keeping the<br />

shop at maximum productivity. It’s a given in our industry<br />

that when the machine isn’t running, the money isn’t coming.<br />

This opens the discussion of long-term flexibility and<br />

it’s the most often overlooked consideration in buying live<br />

tools. You might ask, what work do you currently have in the<br />

shop and what work will be coming in the future? The overall<br />

economies of a changeable adapter system on your tooling<br />

may be a consideration not often made when your focus<br />

is centered on the machine being purchased. Dedicated tools<br />

Multi-spindle tool brings improved cutting capacity<br />

to your lathe<br />

Shown here is a standard BMT cross working tool<br />

for large families of products may often be desirable for some<br />

applications, but do consider whether a flexible changing system<br />

would be more appropriate. Talk to your tooling supplier<br />

for the various options, before making that determination.<br />

If standard ER tooling is suitable for the work, there are<br />

many good suppliers. It is important though, to pay close attention<br />

to the construction aspects noted above. For a quickchange<br />

or changeable adapter system, there are fewer suppliers<br />

in the market, so seek them out and be sure they can<br />

supply the product styles you need for all your lathe brands.<br />

Now, an application example showing clear evidence of the<br />

value of testing live tool performance…<br />

One company was performing a cross-milling application<br />

using an ER 32 output tool on a Eurotech lathe, running<br />

10 ipm at 4000 rpm. They were making three passes with<br />

a cycle time of 262 seconds and were having difficulties with<br />

chatter on the finish, while producing 20,000 pieces per year.<br />

The annual cost of the machining was over $ 130,000. By<br />

using an alternative live tool with an ER 32AX output, internal<br />

collet nut design, with the same parameters, they were<br />

able to produce the part in a single pass with a smooth finish<br />

and cycle time of just 172 seconds. Over the course of the<br />

year, this yielded a cost savings of $ 45,000, approximately<br />

20 x the cost of the tool. The bottom line is the bottom line, as<br />

the accountants tell us.<br />

In the end, you may not need a universal adjustable tool or<br />

a multi-spindle live holder or even a quick-change adapter<br />

system, but do consider all these options. Talk to your machine<br />

builder and several tool suppliers, plus the most important<br />

people in this equation, your shop personnel, as their<br />

input is invaluable to keeping you up and running in a profitable,<br />

customer-satisfying scenario.<br />

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

no. 4, November <strong>2023</strong><br />


materials & tools<br />

New high-performance grade for thread whirling<br />

nent quality. The carbide grade is available for<br />

all standard Horn thread whirling systems.<br />

Furthermore, in-house coating enables fast<br />

delivery times.<br />

The carbide grade SG3P is available for all standard<br />

Horn thread whirling systems<br />

SG3P is the name of the newly developed Horn high-performance<br />

grade offering the user new possibilities in terms of performance<br />

and tool life when whirling medical screws. The new carbide<br />

grade also enables shorter cycle times for thread production thanks<br />

to higher cutting values, including when processing materials that<br />

are difficult to machine.<br />

The combination of an ultra-fine grain carbide powder and the high temperature<br />

resistant coating results in high process reliability and better compo-<br />

The production of bone screws must necessarily<br />

be carried out using a metalcutting<br />

process, as the material for this type of<br />

screw must not be compressed, as is the case<br />

with thread rolling, for example. Particularly<br />

titanium, which is mainly used in the human<br />

body because of its good biocompatibility,<br />

tends to burn when compressing the material<br />

too much. As a machining process, conventional<br />

thread whirling has been done for many<br />

years, being a process mostly used on Swisstype<br />

lathes for manufacturing bone screws, on<br />

a larger scale for the production of threaded<br />

spindles. In the process the rapidly-rotating<br />

whirling head is positioned eccentrically to<br />

the workpiece axis in front of the guide bush<br />

of the sliding-headstock lathe and the slowly<br />

rotating workpiece is guided into the whirling<br />

head with an axial feed movement.<br />

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

High performance in stainless steels<br />

Horn has developed a new, solid carbide milling cutter range especially<br />

for machining stainless steels. The tools are for milling<br />

stainless materials in the food, chemical and pharmaceutical industries<br />

as well as the precision engineering and watchmaking<br />

industries.<br />

In addition, due to their geometry and good chip breaking, the milling tools<br />

are suitable for machining numerous other materials. Due to the precise<br />

combination of the substrate, the macro and micro geometry as well as the<br />

IG3 coating, the milling system exhibits high performance and long tool life.<br />

The coating in particular offers high temperature resistance for machining<br />

steels alloyed with chromium, nickel and molybdenum.<br />

Horn offers the solid carbide milling tools from stock in two types. The<br />

DSHPR variant is suitable as both a finishing and a roughing tool. The geometry<br />

is also adapted for trochoidal machining and plunging. The DSR type,<br />

with its very sharp cutting edge geometry and short design, is suitable for<br />

very small parts and unstable clamping conditions, such as in the medical<br />

and watchmaking industries. In the DSHPR line, all tools are available with<br />

four teeth and in diameters from 2 mm (0.079") to 20 mm (0.787"). Horn<br />

offers the DSR variant with three teeth in diameters from 1 mm (0.039") to<br />

10 mm (0.394").<br />

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

Due to the precise combination of the<br />

substrate, the macro and micro geometry as<br />

well as the IG3 coating, the milling system<br />

exhibits high performance and long tool life<br />

18 no. 4, November <strong>2023</strong>

materials & tools<br />

PCB circuit boards<br />

Cutting –scoring –milling with superior diamond and solid carbide tools<br />

Presented by LACH DIAMANT for the first time in 1977 at<br />

productronica, the portfolio of diamond and carbide tools showcased<br />

at this year’s productronica will captivate visitors with a superior<br />

modern tool range, especially designed for efficient circuit board<br />

production, for the world’s leading manufacturers of electronics.<br />

An example: “Depanelling saws” for stress-free cutting of circuit boards in<br />

multiple production, with highest precision; cutting widths as of 0.3 mm are<br />

achieved. Toothed tools are available with an ultrafine pitch of up to 1.4 mm.<br />

Scoring tools: initially only single-layered boards could be scored effortlessly<br />

with solid carbide tools, but since then there have been major technological<br />

developments. Today fiberglass, ceramics and hybrid materials<br />

are being used; new production technologies made it possible for LACH<br />

DIAMANT to develop a line of high-performance PCD “DreboBlueCut”<br />

scoring saws with superior durability. As usual, all LACH DIAMANT standard<br />

scoring saws, special models and saws with any desired edge geometry<br />

are immediately available or can be delivered on short notice. Hybrid materials<br />

and further challenges: as a global player in the tool industry, LACH<br />

DIAMANT– founded in 1922 – develops and manufactures machining tools<br />

which all leading international electronics manufacturers find indispensable<br />

for efficient production since the first presentation at productronica 1977.<br />

LACH special cutting saws for<br />

stressless depanelling<br />

LACH DIAMANT is perfectly equipped<br />

and prepared, even for new challenges – like<br />

modern hybrid materials, developed with<br />

most diverse properties – electroconductive,<br />

heat-resistant, but also with insulating and<br />

heat-dissipating properties etc.<br />

further information: www.lach-diamond.com<br />

Newly developed diamond and CBN grinding wheels<br />

for previously impossible grinding tasks<br />

A grinding wheel with a metal bond for deep grinding – hitherto<br />

almost unthinkable. For the first time newly developed bond variations<br />

are available for profiling during the deep grinding of carbide,<br />

high-alloyed steel and ceramics in mass production.<br />

What was, up to now, only possible in time-intensive conventional grinding<br />

procedures or with several diamond and CBN grinding wheels, is now<br />

accomplished with only one profile grinding wheel known as “contour-profiled”:<br />

“One for everything“.<br />

The innovative metal bond allows for something never thought possible:<br />

contour grinding from the solid – and with profile depths of up to 15 mm(!),<br />

e. g. bottom blades or profile blades – there is absolutely no impact on tool<br />

life, even at full feed rate. The result: repeatable precision profile cuts in mass<br />

production. The advantage is obvious: significant reductions to a fraction<br />

of the original total cost. The highly developed “contour-profiled” grinding<br />

wheels can even be re-sharpened: for this purpose, LACH DIAMANT<br />

developed a special method which can produce high-precision concave and<br />

convex profiles from 2 to 4 µ.<br />

further information: www.lach-diamond.com<br />

The unique metal bond of the<br />

“contour-profiled” diamond and<br />

CBN grinding wheel makes the process<br />

of deep grinding significantly easier<br />

no.4, November <strong>2023</strong><br />


materials & tools<br />

Solutions for<br />

Advanced Materials<br />

Advanced Materials is a much-used term, but what<br />

does it mean? At Leitz it means materials that are not<br />

made of wood, or wood-based materials, and also have<br />

completely different properties in machining than are<br />

common in woodworking. These include materials for<br />

façade cladding, insulation materials, aluminum, plastics<br />

and composite materials. A broad and constantly<br />

changing field of modern materials, some of which<br />

also requires new machining processes – for which<br />

Leitz naturally always develops the appropriate complete<br />

solutions consisting of tools and services.<br />

Whether as façade cladding for buildings, in the automotive<br />

industry or in aviation – Advanced Materials are extremely<br />

versatile in their application and demanding in their processing.<br />

However, the functional materials are usually more homogeneous<br />

than wood, sometimes very abrasive and it is not<br />

always possible to use a standard tool for machining. In the<br />

field of plastics and composite materials, a further challenge<br />

is the increasing mix of unknown materials, which must be<br />

examined in detail before machining.<br />

Permanent exchange as the cornerstone<br />

for processing recommendations<br />

This makes it all the more important for Advanced Materials<br />

to offer a complete package consisting of competent advice,<br />

individual tests on the material and a wealth of experience in<br />

machining. In close and permanent exchange with users and<br />

machine manufacturers, Leitz specialists examine the desired<br />

materials in order to optimally coordinate processes and<br />

tools and then use this information to create machining recommendations<br />

for the customer. In the case of newly developed<br />

materials or a material mix, machining tests in the Leitz<br />

Technology Center are also elementary. Based on the knowledge<br />

of the specialists from Oberkochen, existing tools are<br />

then either modified or even newly developed.<br />

Optimum solutions for challenging materials<br />

Leitz is presenting a tool that is used, among other things,<br />

for narrow-side machining of HPL materials and fiber-reinforced<br />

plastics. The Diamaster PLUS Z2 router has a negative<br />

axis angle for qualitatively perfect, tear-free edges when<br />

joining and grooving. It has a short, stable cutting edge and<br />

is therefore very suitable for most common panel thicknesses.<br />

As these compact laminates are mostly made of melamine<br />

and phenolic resin impregnated papers or cellulose fibers,<br />

this usually leads to high tool wear. The Diamaster PLUS Z2<br />

router bit therefore has a diamond basic cutting edge, which<br />

ensures a very long service life and thus higher productivity.<br />

In addition, the tool can be resharpened up to eight times.<br />

The Diamaster<br />

WhisperCut<br />

prismatic<br />

rebate cutter<br />

head operates<br />

significantly more<br />

quietly and with less<br />

energy consumption<br />

than conventional rebate<br />

cutter heads<br />

The BrillianceCut circular saw blade for processing acrylic<br />

glass has proven itself exceptionally well on the market.<br />

When sawing this material, scoring, melting or chipping often<br />

occurs on the edge of the sheet. The consequences are<br />

additional work steps to prepare the edge for gluing, polishing<br />

or scarfing. Thanks to the innovative tooth geometry of<br />

the BrillianceCut, users achieve perfect cut surfaces in finished<br />

cut quality already during the splitting process, eliminating<br />

additional work steps, allowing much more efficient<br />

work. Plastic-filled laser ornaments incorporated into the<br />

circular saw blade not only reduce noise, but also ensure increased<br />

running smoothness and stability. The circular saw<br />

blade also has a long service life thanks to the stable tooth geometry<br />

and can be resharpened up to 20 times.<br />

In architecture and industry, aluminum composite panels<br />

are often used when special requirements are placed on the<br />

stability and formability of building elements, on the durability<br />

of surfaces or on weight reduction. The machining of these<br />

materials is a real challenge in many cases. The Leitz range of<br />

tools for processing aluminum composite panels is impressive<br />

in its versatility and performance. For example, carbide<br />

or diamond-tipped circular saw blades for perfect cutting<br />

quality when cutting panels. With the RazorCut Plus circular<br />

saw blade and its high cutting speed the productivity is increased.<br />

Diamond-tipped circular saw blades have a particularly<br />

long service life. The very durable Diamaster PRO router<br />

bit is also diamond-tipped and has a long service life even<br />

with difficult materials. Very high feed rates are possible, reducing<br />

the machining time of the panels and thus increasing<br />

the user’s productivity significantly. The Leitz range for aluminum<br />

composite panels is rounded off with the Diamaster<br />

WhisperCut prismatic folding cutterhead. This tool works<br />

much more quietly and saves energy. The tool, which can be<br />

resharpened several times, is especially suitable for V-grooves<br />

with 90 ° and 135 ° and delivers perfect cutting results.<br />

Leitz knows the importance of new, challenging materials.<br />

At Advanced Materials the specialists from Oberkochen are<br />

once again demonstrating their adaptability and high level of<br />

innovation in order to provide their customers with individual<br />

and optimal solutions for greater efficiency, quality and<br />

productivity.<br />

further information: www.leitz.org<br />

20 no.4, November <strong>2023</strong>

For each titanium the right drill<br />

materials & tools<br />

Mikron Tool presented the new CrazyDrill Cool<br />

Titanium ATC/PTC series at EMO <strong>2023</strong> in Hanover,<br />

which ensures maximum process reliability when<br />

drilling pure titanium and its alloys.<br />

The high-performance material titanium poses a chip removing<br />

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

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

the chip removing process behaviour differs. For these challenges<br />

Mikron Tool has developed drills perfectly tailored to<br />

the respective titanium grades, which can machine titanium<br />

safely, with higher cutting performance results, longer tool<br />

lives and excellent hole quality.<br />

Titanium is highly demanding<br />

Machining the unruly titanium is highly demanding. One<br />

of the reasons is the combination of its properties of high<br />

elasticity and tensile strength. Because of the high toughness,<br />

chip breaking is difficult to achive. Due to its low thermal<br />

conductivity, heat is not dissipated from the cutting area<br />

through the chip. In addition, titanium tends to form builtup<br />

edges. This all leads to higher wear and reduces process<br />

reliability during drilling.<br />

When drilling the challenge is even greater<br />

And drilling is even more titanium challenging than milling.<br />

The viscoelastic property of titanium causes the drill to stick,<br />

and the pressure on the cutting edges increases. This usually<br />

leads to uncontrolled drill breakage. Material sticking on<br />

cutting edges and guide chamfers increase cutting forces, resulting<br />

in cutting edges that can break out. Moreover also the<br />

chip shape is problematic. This is because the titanium chips<br />

tend to compact in the head area and prevent further chips<br />

from flowing in. The high temperature load on the cutting<br />

edges is an additional complicating factor.<br />

Cool the tool!<br />

To reduce the heat in the cutting area, the cooling lubricant<br />

must reach the machining area directly. The two cooling<br />

channels with very large cross-sections carry massive<br />

amounts of coolant to the drill tip and guarantee constant<br />

cooling, including lubrication of the cutting edges. At the<br />

same time the massive coolant jet flushes the chips through<br />

the polished flutes and prevents chip jams.<br />

Innovative cooling concept<br />

The patented special shape of Mikron Tool’s cooling channels<br />

enables a four times higher volume of coolant to be shot<br />

through the tool at the same pressure. This is a further key to<br />

success and stands for innovation in the thermal dissipation<br />

and chip removal technology.<br />

Not all titanium is alike<br />

To process this material efficiently, it is necessary to know it<br />

down to the smallest detail. Mikron Tool has examined various<br />

test materials and discovered that the diverse grades of<br />

titanium are extremely different from each other, which is<br />

of utmost relevance for their industrial machining. Pure<br />

titanium (grades 1 - 4) is characterized by high corrosion resistance,<br />

but has lower mechanical strength. Alloyed titanium<br />

(grade 5 and higher) has high strength but low ductility.<br />

Getting to grips with these differences in terms of machining<br />

technology is a master stroke. Thanks to the meticulous<br />

development work and the knowledge gained from it, the Mikron<br />

Tool engineers found the perfect solution: two specific<br />

geometries, one for pure titanium grades and one for titanium<br />

alloys. In this way perfectly controlled chip removal,<br />

high drilling speeds, long tool lives and repeatable processes<br />

with optimum drilling quality are guaranteed for these difficult<br />

titanium materials.<br />

The new CrazyDrill Cool Titanium – twice as fast<br />

The new CrazyDrill Cool Titanium series is offered in the<br />

diameter range of .039" – 1/4" (1 – 6.35 mm). For pure titanium<br />

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

6 x d. For titanium alloys Mikron Tool relies on drills with<br />

6 x d and 10 x d in combination with a pilot drill.<br />

Product overview<br />

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

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

properties of the various titanium grades.<br />

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

it is of great importance to have high process reliability<br />

and calculable tool live. If the latter can be improved, so<br />

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

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

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

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

in one shot, without multiple machining steps.<br />

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

no. 4, November <strong>2023</strong><br />


news & facts<br />

CERATIZIT acquires Xceliron corp.<br />

Expert in solid carbide special tools for the aerospace industry<br />

CERATIZIT S.A., part of the Plansee Group, has acquired<br />

all shares of Xceliron corp. The Chatsworth, CA<br />

based round tool manufacturer is focused on providing<br />

special solid carbide tools for the aerospace and<br />

automotive industries in the U.S.<br />

“With its high-quality speciality products, the Xceliron portfolio<br />

is an ideal complement to the standard products from<br />

our Sacramento site and an important building block for our<br />

global growth strategy,” says Mirko Merlo, president Americas<br />

at CERATIZIT. Xceliron’s strong foothold in the aerospace<br />

industry not only provides CERATIZIT with a launch pad<br />

to tap into new customer groups, the company’s expertise in<br />

the field of special tools also opens new opportunities to offer<br />

CERATIZIT customers in North America an even more<br />

comprehensive range of tooling solutions in the future.<br />

Management stays on board<br />

The forthcoming integration process will be actively supported<br />

by the company’s founders. “We are very pleased<br />

that Randy Jones and Ric DiOrio will continue the successful<br />

management of Xceliron and act as co-managing directors,”<br />

commented CERATIZIT executive board spokesman<br />

Andreas Lackner on the closing of the transaction.<br />

“We are thrilled to have found the right partner in<br />

CERATIZIT to take Xceliron to the next level and build on<br />

our heritage. Long-term thinking and creativity are two of<br />

About Xceliron corp.<br />

Xceliron corp. (est. 1990) is since more than 33 years a<br />

precision cutting tool manufacturer and solution provider,<br />

excelling in providing innovative solutions for difficult to<br />

machine parts in the aerospace industry as well as<br />

commercial and automotive sectors. From off-the-shelf<br />

to speedy specials to application engineered solutions.<br />

Mirko Merlo, CERATIZIT executive board member Melissa<br />

Albeck, Randy Jones, Ric DiOrio and Andreas Lackner (l. to r.)<br />

the values that have also been at the core of our business over<br />

the past 33 years,” Ric DiOrio and Randy Jones say.<br />

Specialization in the aerospace industry<br />

Xceliron’s reputation for excellence in the aerospace sector<br />

where upmost precision and reliability is required, perfectly<br />

complements CERATIZIT’s commitment to quality and innovation.<br />

This strategic synergy positions CERATIZIT to be<br />

an industry leader in providing aerospace-grade tooling solutions.<br />

Mr. Merlo adds, “This acquisition strategically positions<br />

us to better serve our customers with an expanded range of<br />

custom tooling solutions, specifically tailored to meet the demanding<br />

requirements of the aerospace industry. We are eager<br />

to leverage Xceliron’s expertise and reputation for precision<br />

to drive innovation and excellence in round tools.”<br />

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

Tyrolit strengthens its US-market position<br />

End of September <strong>2023</strong> the Tyrolit Group, a global<br />

leader in abrasive solutions, has acquired all of the<br />

stock of Acme Holding Company. Acme Abrasives is a<br />

specialized abrasives manufacturer and provider based<br />

in Michigan and is now Tyrolit’s seventh manufacturing<br />

plant in the US.<br />

This acquisition will further expand the product portfolio<br />

for the steel and foundry as well as the rail industry. Acme<br />

Abrasives is one of the leading manufacturers in North<br />

America for hot pressed grinding wheels for the steel and<br />

specialty steel industry’s grinding needs. Tyrolit will integrate<br />

Acme wheels in its portfolio of grinding and specialty<br />

abrasive solutions for industrial clients.<br />

CEO Thomas Friess: “We have built a successful global economic<br />

base that allows us to further pursue our strategic direction<br />

of business activities. The further expansion of our<br />

portfolio – especially for crucial industries like steel, foundry<br />

and rail – strengthens our operational competitiveness.”<br />

Commitment to high-quality<br />

“With the addition of Acme Abrasives we will optimize our<br />

customers’ benefit and utilize our global position. Acme perfectly<br />

aligns with our values. We are excited about the opportunity<br />

to offer high-quality products and services for a wide<br />

variety of specific needs”, explains Matthias Kuprian, executive<br />

board member Metal Industries.<br />

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

22 no.4, November <strong>2023</strong>

news & facts<br />

FANUC ships its one millionth robot<br />

FANUC Corporation recently celebrated a significant milestone in<br />

the automation industry by producing its one-millionth industrial<br />

robot. The company which supplies customers worldwide with its<br />

CNC-systems, robots and machine tools, is a pioneer in factory<br />

automation and deployed its first robot in its own production line<br />

back in 1974.<br />

Today thousands of robots build new robots<br />

in the company’s factories in Japan. “Demand<br />

for our robots is currently at an all-time high”,<br />

says Marco Ghirardello, the president and<br />

CEO of FANUC Europe.<br />

While industrial robots were traditionally<br />

used mainly in the automotive and electronics<br />

industries they have now become prevalent in<br />

many other industries and businesses, including<br />

food and pharmaceuticals and even in the<br />

skilled trades. The worsening labor shortage<br />

and the improved user friendliness are some<br />

of the reasons for the spread of robotics into<br />

new segments.<br />

FANUC offers over 200 robot models that<br />

perform various tasks in manufacturing, such<br />

as welding, painting, assembly and packaging.<br />

Collaborative robots (cobots) are gaining popularity<br />

as they can work directly next to or together<br />

with employees without external safety<br />

fences. But traditional production robots still<br />

dominate in the industry, and their use, such<br />

as in the automotive industry, accelerates the<br />

shift towards electromobility.<br />

further information: www.fanuc.eu<br />


Japanese and European innovation for Industry 5.0<br />

GL events and Aichi prefecture, the industrial capital of Japan, have<br />

teamed up to create the SMART MANUFACTURING SUMMIT by Global<br />

Industrie.<br />

This new trade event devoted to Industry 5.0 will include a high-level conference<br />

programme involving speakers from the worlds of research and industry,<br />

as well as representatives from European and Japanese government<br />

bodies, all of whom will play key roles in defining the industrial landscape of<br />

the future.<br />

Moving towards the future<br />

A series of high-level conferences, including tangible case studies, will take<br />

place over the course of three days. They will address a variety of subjects,<br />

including market expectations, the latest trends in Europe and Asia, partnerships<br />

and cooperation, international agreements and public-sector programmes<br />

to support business development.<br />

The first day of the programme will focus on the objectives supported by<br />

both Europe and Japan, while the second day will give an insight into the<br />

different approaches to Smart Manufacturing in Europe and Japan. Presentations<br />

and round-tables will give participants the opportunity to discuss<br />

and learn more about various strategic issues and potential areas of cooperation.<br />

The third day will be devoted to a more technical approach, with presentations<br />

about Industry 5.0 aimed at building<br />

a smart, sustainable future.<br />

Speakers from both continents<br />

Representing the private, public and academic<br />

sectors, all the speakers are experts and decision-makers<br />

willing to share their views about<br />

the industry of the future and industrial cooperation<br />

between Japan and Europe, the issues<br />

and challenges of tomorrow’s industry.<br />

During these three days of conferences,<br />

and during the SMART MANUFACTUR-<br />

ING SUMMIT by Global Industrie in March,<br />

13 – 15, 2024, all the European and Japanese<br />

players involved in “Industry 5.0” are invited<br />

to come together at Aichi Sky Expo, the international<br />

exhibition center of Aichi prefecture,<br />

to discuss and find answers to questions concerning<br />

industrial development, innovation<br />

and cooperation.<br />

further information: www.sms-gi.com<br />

no.4, November <strong>2023</strong><br />


news & facts<br />

A quantum leap in efficiency and sustainability<br />

MAPAL invests in India and expands its capacities. In<br />

Coimbatore, the headquarters of MAPAL India, the<br />

company recently opened a “Green field facility”. The<br />

new company premises set standards in the areas of<br />

production, technology and sustainability.<br />

Since 2015 the headquarters of MAPAL India are in<br />

Coimbatore, a city with over a million inhabitants in the<br />

south of India. “Many of our nationwide customers and business<br />

partners produce here and rely on our products and support”,<br />

emphasises Thanigaraj Sripathy, CEO of MAPAL India.<br />

Business in India and export business is developing well for<br />

MAPAL India. Long-term growth is predicted for the Indo-Pacific<br />

economic region, with positive effects for the machining<br />

industry. “With an eye on the future, we have significantly<br />

expanded the capacities in Coimbatore and invested<br />

in a new company area”, says Dr. Jochen Kress, president of<br />

the MAPAL Group. A production hall, a reception building<br />

and an administration building have been built on an area<br />

of about 8,300 m 2 ; production capacities have now tripled.<br />

Additional space the size of four football fields is available to<br />

ensure an expansion of the site in the coming years. “With<br />

this investment we are strengthening our position as a leading<br />

manufacturer in the upmarket tool segment and significantly<br />

expand our capabilities in India,” Kress emphasises.<br />

Faster, more accurate and more flexible<br />

MAPAL India is successful in many business areas and supports<br />

a loyal customer base, particularly in the automotive,<br />

aerospace, wind power and mining sectors. 160 employees<br />

at five locations coordinate all activities for the domestic<br />

and export market. Special and standard tools are manufactured<br />

at the headquarters in Coimbatore. The focus is on<br />

PCD, fixed and fine boring tools as well as repairs and reconditioning.<br />

Production is done in accordance with the MAPAL<br />

Group’s uniform global quality standards. The ultra-modern<br />

equipment of the new production plant enables even more<br />

precise, safer and more flexible manufacturing processes.<br />

And this with significantly shorter reaction times. “We will<br />

also expand the product portfolio beyond the existing product<br />

range,” announces Kress.<br />

Sustainable production<br />

The greenfield construction was designed and executed with<br />

three clear objectives: zero maintenance (trouble-free production),<br />

zero discharge (wastewater recycling) and green<br />

compliance (environmental sustainability). An intelligent<br />

building control system guarantees optimal manufacturing<br />

conditions and ensures a consistent energy supply. The subsidiary<br />

produces about one third of the required electricity<br />

via photovoltaic systems on company-owned buildings and<br />

parking areas. As a further contribution to environmental<br />

and climate protection, investments were made in highperformance<br />

HVAC systems (heating, ventilation, air conditioning),<br />

resource-saving building materials, energy-efficient<br />

lighting and sustainable landscaping measures. The company<br />

premises are surrounded by a green belt with 1,800 native<br />

trees and plants. These ensure clean air and a dust-free environment.<br />

MAPAL India treats the waste water produced in<br />

the factory and uses it for landscape irrigation.<br />

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

Expanding presence in Canada<br />

ANCA Inc, a leading manufacturer<br />

of grinders used for the creation of<br />

precision cutting tools and components,<br />

is excited to announce the<br />

addition of Brady Roarke to the<br />

America’s based team. Brady will<br />

be located near Toronto, Canada.<br />

This strategic move signifies ANCA’s<br />

commitment to further strengthening<br />

Brady Roarke its operations in the Canadian market<br />

and enhancing its ability to serve clients<br />

across the region. Brady comes to ANCA with an impressive<br />

background in grinding machines, bringing nine years of ex-<br />

perience and a proven track record of success as an applications<br />

engineer. Five of those years were spent milling, and<br />

four were spent grinding.<br />

As the newly appointed applications engineer & technical<br />

sales expert, Brady will play a pivotal role in expanding ANCA’s<br />

reach in the grinding industry in Canada, both with new opportunities,<br />

and expanding relationships with its existing<br />

client base in the region.<br />

The addition of Brady is part of the companies larger strategic<br />

plan to expand its footprint and enhance its offerings<br />

in Canada. This move underscores ANCA’s commitment to<br />

delivering top-tier solutions and services that meet the evolving<br />

needs of its Canadian clients.<br />

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

24 no.4, November <strong>2023</strong>

CERATIZIT appoints new president of the<br />

Regional Unit Asia Pacific<br />

news & facts<br />

CERATIZIT is pleased to announce the appointment of Mr. Andreas<br />

Fritz as president of the CERATIZIT Regional Unit Asia Pacific.<br />

In his new role Mr. Fritz will oversee all CERATIZIT production and sales<br />

sites across Asia as well as leading sales of branded cutting tool products<br />

throughout the region.<br />

With over three decades of experience in leading positions in the cutting<br />

tool industry, Mr. Fritz brings a wealth of expertise to his new position.<br />

“Today Asia is already an enormously important market for CERATIZIT<br />

and still offers a great deal of growth potential moving forward,” said Mr.<br />

Andreas Fritz. He will play a pivotal role in further strengthening the company’s<br />

presence in Asia and capitalizing on the region’s immense growth<br />

opportunities to further establish the brand as a market leader.<br />

Beyond its strong position on the Indian market, CERATIZIT has a<br />

very robust foothold in China and other Asian countries through the<br />

CB-CERATIZIT joint venture, a fact that is especially true for the Hard<br />

Material Solutions segment. The local know-how coupled with the sales and<br />

production network CB-CERATIZIT form a solid foundation to further<br />

drive growth in the region. As part of the company’s global effort to become<br />

the sustainability leader in the hard metal and cutting tool industry,<br />

Mr. Fritz will also lead the implementation of sustainable practices across<br />

CERATIZIT’s operations in Asia.<br />

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

Andreas Fritz<br />

Business network in Vietnam<br />

Creation of “Italian Manufacturing Technologies”<br />

The founding act of IMT-Italian Manufacturing Technologies, the<br />

first business network in Vietnam among UCIMU member enterprises,<br />

was signed on July, 20, 2024.<br />

The network was signed by seven companies: Buffoli Transfer (Brescia), Ficep<br />

(Gazzada Schianno, Varese), Gerardi (Lonate Pozzolo, Varese), Innse Berardi<br />

(Brescia), Losma (Curno, Bergamo), Prima Industrie (Collegno, Turin),<br />

Rettificatrici Ghiringhelli (Luino, Varese).<br />

The initiative was created with the aim of supporting the network companies<br />

in their activities of presence and penetration in one of the Asian<br />

markets with the highest development potential, also because it is considered<br />

the gateway to the ASEAN area. The initiatives by the network will be based<br />

in Ho Chi Minh City and with the collaboration of local experts will materialize<br />

into promotional activities to support the participation of the network<br />

companies in sector exhibitions, as well as into the organization of visits to<br />

potential user companies, of seminars and networking meetings among the<br />

seven Italian enterprises and local operators, not only from Vietnam.<br />

Barbara Colombo, president of UCIMU-SISTEMI PER PRODURRE asserted:<br />

“I am very satisfied with the creation of IMT, which comes after two<br />

years of intense work and a careful analysis of the market situation, conducted<br />

also through the issue of a monograph dedicated to the country, in<br />

addition to a study tour in the main areas of Vietnam”.<br />

IMT is an operational means for the internationalization of companies interested<br />

in working in the South-East Asian region. Based on the processing<br />

of CECIMO and Gardner data by the UCIMU<br />

Economic Studies Department & Business<br />

Culture Center, in 2022, the ASEAN countries<br />

saw their machine tool consumption grow by<br />

about 20 %, thus extending the positive trend<br />

registered from 2021.<br />

With specific reference to Vietnam, consumption–<br />

up by 34 % in 2022 – should remain<br />

almost stationary in <strong>2023</strong> (+ 2 %). According<br />

to the forecasts elaborated by UCIMU on the<br />

basis of Oxford data, the demand for machine<br />

tools should then grow considerably in 2024<br />

(+ 13 %), in 2025 (+ 12 %) and in 2026 (+ 11 %).<br />

The IMT initiative represents the second<br />

network of UCIMU member companies. This<br />

is added to ITC India, a network that operates<br />

since 2012. ITC India was created with the<br />

support of UCIMU for its member enterprises<br />

and then also opened to the participation of<br />

the member companies of AMAPLAST and<br />

ACIMGA, which participate in the initiative,<br />

even if they do not currently have any representation<br />

of enterprises in the network.<br />

further information: www.ucimu.it<br />

no.4, November <strong>2023</strong><br />


processes<br />

Radically faster tool manufacturing<br />

Things are happening in Trossingen, but hello.<br />

After the promising presentation of the Multigrind®<br />

Radical at GrindingHub in Stuttgart last May, the<br />

high-tech tinkerers from the Black Forest are doing<br />

even better. The gamechanger for all tool manufacturers<br />

now also presents an ultra-compact, super-fast<br />

automation system.<br />

So we ask. How has the market reacted on the new tool grinding<br />

machine? Is there any initial customer feedback? What<br />

can automation do and why do people in Trossingen talk<br />

about the best tool grinding machine in the world?<br />

Our conversation partner Thomas Bader, technology<br />

pioneer and managing director of Adelbert Haas GmbH, is<br />

visibly proud of the new compact tool grinding machine.<br />

Mr. Bader, the Multigrind® Radical set out to make<br />

tool grinding faster, easier and more flexible,<br />

as well as more economical and precise. Have you<br />

been able to deliver on this promise? And what<br />

do the first users tell you about this lucky bag?<br />

Thomas Bader: Faster, more precise, more flexible, more<br />

economical etc. That’s not what we were looking for when<br />

we designed the Multigrind® Radical. With a new tool<br />

grinding machine from Trossingen, better performance<br />

values are a matter, of course, and therefore predictable.<br />

We wanted nothing less than to revolutionize, transform<br />

and thus lead tool manufacturing into the future. Hence the<br />

name Multigrind® Radical and the nickname ‘Gamechanger’.<br />

With the perfect choreography of software and hardware,<br />

we succeeded perfectly.<br />

Thomas Bader<br />

The first Multigrind® Radical machines are now<br />

at customers’ sites. What do they say about the<br />

gamechanger?<br />

Thomas Bader: The best compliment so far came from a<br />

customer from the Swabian Alb. He said: ‘Now I not only<br />

have a Porsche in front of my door, but also one in the<br />

production hall. And the difference? The Multigrind® Radical<br />

has more endurance and makes money.’ As an engineer<br />

I am particularly happy about the Porsche compliment. Of<br />

course also under the aspect of ‘grinding more beautifully’.<br />

All joking aside: we have received positive feedback across<br />

the board. Only the wish for fast and really uncomplicated<br />

automation was still unfulfilled. Now we have added this.<br />

How do you integrate powerful automation into<br />

such a compact machine?<br />

Thomas Bader: That was the challenge. An outstanding<br />

feature of the Multigrind® Radical is its extremely compact<br />

design. With a minimum footprint of around 2.7 m 2 and<br />

a height of just over 2 m, it is ideal for the smallest of hall<br />

environments. With integrated automation the footprint<br />

increases to just 3.7 m 2 .<br />

In return, the customer gets a fully automated and<br />

super-fast production unit with built-in productivity<br />

enhancements that set new standards in manufacturing.<br />

Regardless of whether they are grinding straight rotary<br />

or plate molds. And the new fast is also incredibly easy to<br />

handle. (Thomas Bader laughs) Remember, a Radical doesn’t<br />

take breaks, it just gives the tool time to recover.<br />

Why don’t you tell us some specific performance data?<br />

Thomas Bader: Well here are a few superlatives. We<br />

drastically reduce non-productive time. Due to the parallel<br />

26 no.4, November <strong>2023</strong>

processes<br />

tool and grinding wheel change, we save an enormous<br />

amount of time and manage this discipline in just a few<br />

seconds. Milling cutters, plates and drills are ground as<br />

required. In large quantities or as a very small series from<br />

batch size 1 to 1,000. Previously unrecognized potential<br />

is raised here.<br />

Assume that you produce 2,000 h per year in a single-shift<br />

operation. Then, with an average machining time of 4 min<br />

per cutter, you will produce 30,000 cutters per year in singleshift<br />

operation. If you manufacture in two shifts, you will<br />

produce 60,000 cutters, and in three shifts 90,000 cutters.<br />

The industry average for a tool grinding machine is 30 s<br />

for workpiece change and 15 s for tool change. A Multigrind®<br />

Radical, on the other hand, requires 8 s for the workpiece<br />

change and 3 s for the tool change. If we now assume that<br />

the workpiece has to be changed once and the tool twice to<br />

produce a milling cutter, the Multigrind® Radical saves 46 s<br />

in non-productive time. This results in a savings potential<br />

of around 77 % compared to the industry average. At an<br />

hourly rate of 80 €, the Multigrind® Radical saves -.50 € per<br />

workpiece change and -.26 € per tool change. That pays for<br />

itself immediately.<br />

In addition the machine can be quickly integrated into<br />

production. This can be completed within a few hours,<br />

i.e. without any loss of time and without any major<br />

programming effort. Parameterization, templates and ERP<br />

information are provided immediately by Multigrind®<br />

Horizon software. This means that no control is required<br />

and the gamechanger is immediatly ready for production.<br />

All that’s left to do is quickly feed in the parts via automation<br />

and off we go. This is definitely rock around the clock.<br />

Rock around the clock, you’re referring to<br />

unmanned production, right?<br />

Thomas Bader: With the Multigrind® Radical, we want<br />

to push the boundaries. A tool grinding machine without<br />

limits. Thanks to its compact appearance, it is also perfect<br />

as a solo performer for a garage start-up. The real purpose of<br />

the Multigrind® Radical is to combine several tool grinding<br />

machines into a hyper-profitable production cluster. Imagine<br />

5 or 10 Multigrind® Radical side by side, there’s a lot going<br />

on. This makes flexible, fully automated, unmanned series<br />

production the production standard.<br />

Freedom and maximum control<br />

And why do people in Trossingen talk about the<br />

best tool grinding machine in the world?<br />

Thomas Bader: Exactly that was our claim. We set out to<br />

design and then build the best tool grinding machine in the<br />

world with the Multigrind® Radical. Operated by powerful<br />

software that regulates everything in the background and<br />

only serves to control everything in the foreground.<br />

When, as in this case, aspiration and reality correspond,<br />

it’s fair to call a spade a spade, isn’t it? And anyone who<br />

Radical 830XW<br />

knows Adelbert Haas knows that we only develop something<br />

new if we can fundamentally improve what already exists,<br />

otherwise we leave it. The time was ripe and we delivered.<br />

Ultimately of course, it’s our customers who decide. Only<br />

when they talk about the best tool grinding machine are we<br />

satisfied and continue to tinker with the next big thing.<br />

What prompted Adelbert Haas to develop just now a tool<br />

grinding machine? The other Multigrind® machines are,<br />

as the brand name suggests, rather high-tech grinding<br />

machines with multiple applications. From medical<br />

technology and aerospace to pumps and materials<br />

handling.<br />

Thomas Bader: It’s like always at Adelbert Haas, our<br />

customers challenge us and we then try to exceed their<br />

expectations.<br />

And when it comes to tool grinding, this meets a very, very<br />

long tradition in our company. As early as 1938, the HS 1<br />

tool grinding machine was presented at the industrial trade<br />

fair in Leipzig and repeatedly improved in the following<br />

centuries.<br />

In 1984 we then developed the first CNC 2-axis tool<br />

grinding machine and replaced it in 1989 with the 5-axis<br />

type HB 3045-5. The successful Multigrind® HT was born<br />

in 1998. Many of these fossils are still doing a good job<br />

and some are being brought up to date through our retrofit<br />

program. Of course these retrofit machines do not make a<br />

fair comparison with the new Multigrind® Radical; they are<br />

worlds apart.<br />

Anyone who has to face the competitive pressure of<br />

automated production today definitely cannot do without<br />

a Multigrind® Radical. That’s why, when it comes to tool<br />

grinding, we have gone back to our roots, taken our<br />

customers’ wishes seriously and followed our premise.<br />

Who, if not us? When, if not now, and where, if not<br />

here in Trossingen?<br />

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

no.4, November <strong>2023</strong><br />


processes<br />

Big parts with equally big challenges<br />

Giga castings in CNC machining<br />

It has revolutionized automotive production: in<br />

giga casting large structural automotive components<br />

are produced in one piece, using high pressure die casting.<br />

The process is a challenge – not only for die casters.<br />

The following article sheds light on why the machining<br />

of giga components is a difficult undertaking and how<br />

solutions coul look like.<br />

Following Tesla’s success, companies like Volvo are following<br />

suit: in giga or mega casting, structural components such<br />

as the underbody of a car are no longer welded, glued or<br />

screwed together from many individual parts, but cast in one<br />

piece. The process drastically reduces the number of components<br />

produced and eliminates most joining operations. This<br />

results in savings throughout the production chain. In addition,<br />

giga components reduce the weight of a vehicle, which is<br />

particularly advantageous in the field of electromobility: less<br />

weight means greater energy efficiency and therefore a longer<br />

range for the vehicles.<br />

However, these advantages are accompanied by complex requirements<br />

in production. Many of them come from the die<br />

casting itself, from the huge casting molds and their temperature<br />

control to subsequent cooling and the associated component<br />

distortion. Even after the die casting has been successfully<br />

completed, giga components remain challenging,<br />

as product manager Michael Kreuzberger from SW points<br />

out: “Discussions about giga casting have mainly focused on<br />

the die casting process itself up to now. However, the complexities<br />

of giga components go further. Machining these<br />

large castings also presents several challenges that need to be<br />

considered.”<br />

Large machines, high space requirements<br />

Some companies have already developed special large machines<br />

for die casting, such as Tesla’s Giga Press. Reality<br />

is much different when it comes to CNC finishing. It is<br />

often still done on portal milling machines from the largeparts<br />

manufacturing industry. “The components from giga<br />

castings are simply much too large for conventional CNC<br />

machining centers. The parts don’t fit in the machines”,<br />

says Kreuzberger. “On the other hand, the systems from<br />

large- parts manufacturing are actually too large and too<br />

sluggish. Efficient machining is hardly possible on these single-spindle<br />

portal milling machines. Machining times are too<br />

long and loading and unloading is too time-consuming.”<br />

So, on the one hand, companies face enormous space problems.<br />

After all the die casting machines required for giga<br />

casting alone can reach the size of a house. Add huge portal<br />

milling machines to that and many production halls quickly<br />

reach their limits. And only few companies have the same option<br />

as Tesla, namely building a new, greenfield production<br />

hall of the necessary size.<br />

Cycle times do not meet automotive requirements<br />

Even if sufficient space is available for large portal milling<br />

machines, their long machining times are problematic in the<br />

fast-cycle automotive industry. One reason for this is the use<br />

of ball screws to translate rotary motions. Kreuzberger explains:<br />

“In aluminum machining the non-productive times<br />

are significantly higher than the pure machining times. The<br />

larger the workpieces are, the longer the distances the feed<br />

axes have to cover, for example during a tool change. Since<br />

ball screws have lower accelerations and speeds, the non-productive<br />

times get even longer.” In short, machines from the<br />

large-part production sector generally cannot deliver the<br />

cycle rates required in the demanding automotive industry.<br />

Herein lies a major challenge in machining giga parts: achieving<br />

typical speeds for the automotive industry on workpieces<br />

this large.<br />

Another challenge lies in the sensitivity of the components.<br />

Since die casting creates stresses in the workpiece, large-volume<br />

castings are susceptible to warpage. In electric cars in<br />

particular, the wall thicknesses of the components have to be<br />

Structural part – top<br />

Underbody<br />

28 no. 4, November <strong>2023</strong>

processes<br />

E-car<br />

as thin as possible in order to save weight. This adds to the<br />

warping risk. “The precision of the machine is not the problem.<br />

Both large portal milling machines and smaller machining<br />

centers can easily achieve the required accuracies”, clarifies<br />

Kreuzberger. “Rather, it is a question of optimally matching<br />

the workpiece to the clamping device in the machining<br />

center and the gripper technology to avoid distortion during<br />

machining.”<br />

Higher speed thanks to linear motor<br />

A solution for the sensitivity of giga components during machining:<br />

“The clamping device must be developed specifically<br />

for the respective component to fit exactly. Close cooperation<br />

with the machine manufacturer is crucial for the best<br />

individualized result”, says Kreuzberger. “At SW we have our<br />

own department that is exclusively concerned with ensuring<br />

optimum coordination between the clamping device and the<br />

workpiece in close consultation with our customers.”<br />

Things get more complex when it comes to the challenge<br />

of required cycle rates. Here suitable machines with high dynamics<br />

and the necessary space for the giga components are<br />

required. In any case, users should opt for systems with linear<br />

motors. The direct drive of a linear motor generates the desired<br />

movements without mechanical transmission elements.<br />

As a result it achieves maximum accelerations and the highest<br />

traversing speeds, while also operating wear-free. “The<br />

fastest CNC machines on the market all use linear and torque<br />

motors, including most of our own machines”, Kreuzberger<br />

says. “We also rely on a weight-optimized design. This allows<br />

us to minimize non-productive and cycle times. Our<br />

machining centers achieve acceleration values of over 2 g and<br />

rapid traverse speeds of 120 m/min.” To harness this speed for<br />

larger workpieces, SW launched the BA space3 in 2021. The<br />

machine combines high cycle speeds with the space needed<br />

for large castings. Only multi-spindle machines are faster.<br />

New SW machine focuses on<br />

multi-spindle capability<br />

Currently there are hardly any multi-spindle machines for<br />

large castings on the market. But SW is already working on<br />

a machine that will introduce two spindles into its ‘space’<br />

series. “In contrast to our other multi-spindle machines, the<br />

two spindles will operate completely independently of each<br />

other”, says Kreuzberger. “We are using two autonomous<br />

three-axis units to allow maximum flexibility with different<br />

components.” For medium-size components both spindles<br />

can each work parallel on one component as usual. For larger<br />

components where only one workpiece fits in the machine,<br />

both spindles can work simultaneously on the same piece and<br />

change tools independently of each other. A double swivel<br />

carrier allows for parallel loading and machining, and ensures<br />

a further reduction in cycle time. So giga parts like the<br />

rear underbody of a Tesla can be machined in just 1.5 min<br />

– almost twice as fast as with single-spindle machines.<br />

“With the rapid development of electromobility, giga-casting<br />

will continue to gain in importance over the next few<br />

years”, concludes Kreuzberger. “Other automotive manufacturers<br />

are also currently examining the advantages and disadvantages<br />

of using large castings. Asian original equipment<br />

manufacturers (OEMs) in particular are already relying<br />

heavily on giga castings and are successfully installing them.<br />

We want to do our part to ensure that the advantages of this<br />

process outweigh the disadvantages and that the machining<br />

challenges can be easily overcome as well.”<br />

further information: www.sw-machines.com<br />

no. 4, November <strong>2023</strong><br />


processes<br />

Functionally integrated implants through<br />

novel synchronized machining processes – ZykloMed<br />

With the joint project funded by the Federal Ministry<br />

of Education and Research (BMBF), the participating<br />

partners INDEX, Paul Horn GmbH, Beutter<br />

Präzisions-Komponenten GmbH and the wbk Institute<br />

for Production Engineering at the Karlsruhe Institute of<br />

Technology (KIT) are demonstrating their expertise in<br />

the medical industry.<br />

Using new and modern manufacturing processes, the partners<br />

have tackled the challenges for economical machining<br />

of implants with multifunctional as well as non-round bionic<br />

designs. The focus was on the three manufacturing processes<br />

of eccentric turning, polygon turning and turn whirl milling.<br />

Modern medical implants for orthopedics, traumatology<br />

and dental technology are characterized by rigorous demands<br />

on strength, biocompatibility and bionic-optimized geometry.<br />

The geometry of an implant is adapted to the bone and tissue.<br />

In the process, the functional surfaces of the implants<br />

are given an increasingly sophisticated design in order to facilitate<br />

their attachment in the body and make them less invasive<br />

for the patient. The new designs of implants drive up<br />

manufacturing costs because the surfaces are no longer circular<br />

or square. They have more curved surfaces and functional<br />

elements with continuous transitions in a very small<br />

space. In particular the need for several manufacturing steps<br />

on different machines causes costs to rise significantly. For<br />

example, precise handling for exact re-clamping of a workpiece<br />

represents a considerable cost factor. Therefore, despite<br />

the high level of functional integration, an efficient process<br />

route is needed for economical production.<br />

Novel processes<br />

The novel manufacturing processes of eccentric turning,<br />

polygon turning and turn whirl milling are all based on the<br />

same kinematic principle of multiple synchronized rotating<br />

axes. While this principle is well known, its application to<br />

non-circular and curved shapes is highly demanding. At the<br />

same time, the practical implementation must meet the high<br />

quality requirements of the medical industry.<br />

The project partners researched and developed new manu -<br />

facturing procedures along the entire process and supply<br />

chain, from the machines and control technology to the tool<br />

design to prototype and pre-series production. The manufacturing<br />

processes were simulated and designed on known<br />

methods with the same mathematical principles in order to<br />

determine the requirements for tool and machine. The tests<br />

were divided into equivalence tests under laboratory conditions<br />

as well as pre-series tests and near-application environments.<br />

The engineers focused on both machine and tool<br />

technology for the development and design of the individual<br />

processes.<br />

In eccentric turning a rotating non-circular tool is guided<br />

along a rotating workpiece under positional coupling. The<br />

Polygon turning produces non-round contours on lathes<br />

speeds are brought into a certain ratio to each other. The outof-round<br />

shape is thus reproduced on the component within<br />

certain limits, making the production of eccentric outer contours<br />

possible. The rotation of the tool reduces the thermal<br />

load at the cutting edge, which ensures long tool life. The process<br />

also enables the production of tapered profiles.<br />

Polygon turning is a process for producing non-circular<br />

external and internal contours with the shape of a hypotrochoid.<br />

Like rotary eccentric turning, the process offers the<br />

possibility of producing non-circular contours on lathes. In<br />

the process the parallel axes of the workpiece and the tool are<br />

offset from each other by an axial distance and are brought<br />

into a specific speed ratio under positional coupling. The axial<br />

distance, the speed ratio of the workpiece to the tool and<br />

the cutting diameter of the inserts define the dimension of<br />

the contour. A tool system for polygon turning is individually<br />

adapted to the contour of the workpiece to be produced.<br />

Turn whirl milling is the process for producing threads for<br />

bone screws. One or two circular milling cutters are set at a<br />

certain angle to the workpiece. The directions of rotation of<br />

the cutters and the workpiece can be the same or opposite.<br />

The speed ratio of the workpiece to the two cutters depends<br />

on the number of threads and the number of cutter inserts.<br />

Turn whirl milling can also be used to produce economically<br />

threads with a true variable pitch by dynamically changing<br />

the thread profile.<br />

Tests close to series production successful<br />

With successful tests the partners of the ZykloMed pro ject<br />

have made a big step to the goal of the research project, the<br />

economic production of implants of multifunctional and<br />

non-round bionic design. It was proven that the synchronized<br />

manufacturing processes enable the economic production<br />

of modern implants. Additionally to the production of new<br />

component geometries, the processes also offer optimization<br />

potential for the economic production of existing im plants,<br />

as possible applications beyond the medical industry.<br />

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

30 no. 4, November <strong>2023</strong>

processes<br />

Strong partners continue success story<br />

with HiPIMS<br />

The tool manufacturer Horn has been coating its cutting<br />

tools with HiPIMS high-performance coatings in its own<br />

coating center since 2015. From the very beginning the company<br />

has relied on market-ready solutions from CemeCon.<br />

Now Horn has received seven new CC800® HiPIMS systems<br />

for its in-house coating center – including peripherals for<br />

pre- and post-treatment of shank tools.<br />

The quality of its cutting tools is the key to the market success<br />

of Paul Horn GmbH. In 70 countries on six continents,<br />

companies in the automotive industry, chemicals, aerospace,<br />

medical technology or in tool and mold making use the precision<br />

products of the Tübingen-based company.<br />

The high-performance coatings of the tools play a major<br />

role in the success. The company’s own coating center at the<br />

site offers Horn maximum flexibility, also in the development<br />

of new coating solutions. And what makes many of the tool<br />

manufacturer’s customers particularly happy is that fast delivery<br />

times are also possible for special tools and specific<br />

small series. From the very beginning on the partner for the<br />

operation of the systems has been the specialist CemeCon,<br />

having developed the HiPIMS high-performance coatings to<br />

market maturity and economic efficiency. “For the current<br />

expansion and modernization of our coating lines there was<br />

no doubt that we would once again rely on proven expertise,”<br />

says managing director Markus Horn, appreciating the cooperation<br />

with the technology and market leader.<br />

Complete coating center from a single source<br />

With seven new CC800® systems, Horn is sustainably expanding<br />

its coating capacities in HiPIMS technology. Major<br />

parts for the pre- and post-treatment of shank tools, such as<br />

cleaning systems, blasting technology and quality control,<br />

also come from the plant manufacturer CemeCon. Horn intends<br />

to take full advantage of the “more” in autonomy and<br />

performance gained with the support of its strong partner.<br />

CemeCon will continue to supply all consumables and take<br />

over maintenance services as well as individual user training<br />

and support. Furthermore, in addition to the operational<br />

business, the joint focus is on expanding the cooperation in<br />

research and development as well as the combined strategic<br />

development of new business fields for Horn’s cutting tools.<br />

Markus Horn is firmly convinced: “It is key partnerships like<br />

this with innovative strength that pave the way for us to remain<br />

successful in a dynamic market.”<br />

After all, CemeCon is also well aware of the challenges involved<br />

in manufacturing precision tools. “A large proportion<br />

of the tools manufactured at Horn are solutions that are<br />

directly adapted to specific machining processes,” knows<br />

Inka Harrand, the responsible product manager at CemeCon.<br />

The right premium coating is just as important as the geometry<br />

and the material of the tool itself: “Only the interaction<br />

creates a solution that guarantees quality and enables productivity<br />

and durability.”<br />

Efficient in day-to-day business – highly flexible<br />

in coating material development<br />

The new CC800® HiPIMS systems with their open technology<br />

are ideal for the changing requirements that characterize everyday<br />

life at the Tübingen coating center. Clear user interfaces<br />

and fast batch changes make work efficient even with<br />

small batch sizes and complex mold shapes. Handling the<br />

original CemeCon targets, which are an elementary building<br />

block for the production of the coating materials, is also very<br />

easy. As a result, the company produces completely smooth,<br />

droplet-free and low residual stress coatings with maximum<br />

adhesion and uniform coating thickness distribution of 1 to<br />

8 µm for all tool sizes – technically possible even up to 12 µm.<br />

New coating materials can be developed quickly, precisely<br />

and economically from combinations of many elements of<br />

the periodic table. Coatings can be finished directly on an industrial<br />

scale. “In this way, we as a tool manufacturer have<br />

the flexibility to react immediately to changing markets, new<br />

customer requirements and – what is even more – to cover entirely<br />

new fields of application,” says Dr.-Ing. Matthias Luik,<br />

head of research and development at Horn, who is delighted<br />

with the potential of the HiPIMS coating systems. “We are<br />

thus securing important competitive advantages in the market<br />

and creating tangible benefits for our customers.”<br />

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

no. 4, November <strong>2023</strong><br />


machining center<br />

HELLER 360 ° solutions at EMO <strong>2023</strong><br />

At the heart of HELLER’s presentation at EMO was<br />

a 360 ° performance – a holistic view of the demands<br />

placed on modern production. To meet these demands,<br />

HELLER focuses on five solution areas. In addition<br />

to the F 6000 5-axis machining center from the latest<br />

generation of the F series, HELLER presented products<br />

for the digitalization and automation of production, a<br />

comprehensive range of services as well as innovative<br />

manufacturing processes and technologies for complete<br />

machining on a single machine.<br />

HELLER’s commitment is to provide customers with machines<br />

and systems that enable them to produce reliably and<br />

at competitive per-piece costs in their day-to-day operations.<br />

The company based in Nürtingen meets these requirements<br />

with integrated manufacturing solutions that are suitable for<br />

a wide range of industries. “We are successfully transferring<br />

the high demands of the automotive industry to other exciting<br />

sectors,” says CEO Dr. Thorsten Schmidt. This is also reflected<br />

in the distribution of HELLER’s order intakes in the<br />

first half of <strong>2023</strong> according to industries and workpieces.<br />

Schmidt explains: “42 % of our order intakes come from<br />

general mechanical engineering, power engineering, aerospace<br />

and tool and mould making, among others. The truck<br />

and agricultural sector accounts for 29 % of new orders,<br />

while passenger cars still account for 3 %. Non-combustion<br />

engine-related orders for heavy-duty and light-duty vehicles<br />

accounted for 26 % of the total. Our aim is to expand into<br />

even more industries – and EMO offered us a great opportunity<br />

to do so.”<br />

5-axis machining center F 6000 –<br />

designed for production<br />

The 5-axis machine with head kinematics is designed from<br />

the ground up for flexible, powerful series production. Like<br />

all of the companies machines it sets a benchmark for cutting<br />

performance and precision. Highlights include free chip fall,<br />

short idle times, optimum automation capability and compatibility<br />

with the H and FP series for a wide range of workpieces.<br />

The F 6000 also boasts first-class equipment, a small<br />

footprint with a width of 3.70 m and expandability with technologies<br />

such as Mill-Turn, interpolation turning or power<br />

skiving. Dr. Manuel Gerst, head of the development group,<br />

adds: “With the F 6000 we have succeeded in raising the<br />

already high standard to a new level. This is also thanks to<br />

newly developed key components ‘Made by HELLER’. These<br />

include the completely redesigned swivel heads, including the<br />

integrated motor spindles specially developed by the company.<br />

The Speed Cutting Unit (SCU) in combination with the HSK-<br />

A 100 tool shank reaches speeds of 15,000 rpm. As an alternative<br />

HELLER offers the Dynamic Cutting Unit (DCU) designed<br />

for universal use with 380 Nm and 12,000 rpm. For<br />

heavy-duty machining, the Power Cutting Unit (PCU) with a<br />

gear spindle and 1,150 Nm is still available.”<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 />

with speeds up to 700 rpm plays a key role. In line with the<br />

trend towards complete machining this eliminates the need<br />

for reclamping on separate turning machines. The result is<br />

improved workpiece accuracy and significantly reduced cycle<br />

times, especially for series products. The pallet changer is included<br />

as standard as the first level of automation. The new<br />

‘Automation-ready’ option enables easy integration of the<br />

rotary pallet storage (RSP) and HELLER’s standardized linear<br />

magazine solutions at a later date.<br />

Another great strength of the F 6000 is its ease of use. The<br />

comfortable main operating unit in console design with<br />

32 no. 4, November <strong>2023</strong>

machining center<br />

24-inch touch screen, together with other features, ensures<br />

that the operator quickly gets to grips with the machine. In<br />

addition, the significantly wider door to the work area makes<br />

it easier to access the workpiece. New processes can also be<br />

set up quickly and safely on the machine with the optional<br />

SETUP Assist. The new Siemens SINUMERIK ONE control<br />

is available as standard. Existing NC programs from F and C<br />

series machines with SINUMERIK 840D sl can directly and<br />

easily be transferred by the user.<br />

Automation solutions –<br />

flexible, value-adding, competitive<br />

On show at EMO was the RSP 12H6 rotary pallet storage.<br />

With a total of 11 pallet storage locations as standard, the<br />

automation solution enables flexible and automated handling<br />

of machine pallets and is predestined for series production of<br />

small and medium batch sizes. A third level can be added to<br />

extend the solution to up to 17 storage locations plus loading<br />

station. Augmented Reality was on the booth to demonstrate<br />

its functionality and expandability.<br />

The RZ50 robot cell from the companie’s automation portfolio<br />

also provides an insight into flexible robot automation<br />

for automatic loading and unloading of workpieces, fixtures<br />

and pallets, as well as the automation of other handling tasks.<br />

Also presented was the Automation Calculator. It allows<br />

users to enter workpiece data, production information or the<br />

desired machine into a touch-enabled terminal and then receive<br />

recommendations on the most suitable automation solution<br />

and the associated payback time.<br />

Fit for the factory of the future –<br />

digitalization<br />

With a new intuitive operating concept, the HELLER Services<br />

Interface ensures transparency in manufacturing, maintenance<br />

and service processes throughout the entire lifecycle<br />

of the machine. This option can also help reduce machine<br />

downtime by providing evaluations and statistics.<br />

Visualization of specific machine status information, including<br />

status indicators for axes, spindles or other assemblies,<br />

enables users to determine the wear status and take preventive<br />

action to reduce unplanned downtime.<br />

The digital twin provides customers with a digital image of<br />

their machine. The simulation behaves exactly like the real<br />

ma chine, and so saving much time and money during development,<br />

commissioning and optimization. For example, the<br />

use of tested workpiece programs prevents machine damage.<br />

The HSU motor spindle with face contact check ensures<br />

improved production quality in single-part and series production.<br />

Contamination in the HSK tool interface is accurately<br />

detected – chips as small as 10 µm can be detected both<br />

in the taper and on the face contact.<br />

Experience meets innovation – HELLER know-how<br />

One key to higher productivity is complete machining on a<br />

single machine. That is why the specialists are in the process<br />

of integrating different technologies into the current range<br />

of machining centers.<br />

On the F 6000 5-axis machining center various turning<br />

operations, power skiving gear cutting technology, trochoidal<br />

milling, simultaneous 5-axis machining and an external<br />

cylindrical grinding operation was presented as part of a<br />

performance and technology demonstration in C45 steel.<br />

Service – lifetime partnership<br />

With the Full Service Essential, the Nürtingen-based machine<br />

tool manufacturer offers its customers an attractive<br />

package for complete cost control: for new machines, all<br />

maintenance costs are included for a full three years, from<br />

service calls to spare and wear parts, as well as annual manufacturer’s<br />

maintenance.<br />

The Blue retrofit solutions provide customers with energy<br />

efficiency packages that effectively reduce operating costs<br />

and minimize unit costs. The Blue Power Save, for example,<br />

ensures that auxiliary units such as pneumatics, cooling<br />

and lighting are switched off in stages as required. With the<br />

Blue Coolant the energy consumption of the high-pressure<br />

coolant pump can be reduced depending on the machining<br />

process. The Blue Chill combines a powerful cooling unit<br />

with a matching heat exchanger to equip machines for maximum<br />

energy efficiency.<br />

From now on customers in other European countries will<br />

also be able to use the myHELLER customer portal to keep<br />

track of their entire machine fleet all of the time. Spare and<br />

wear parts can be ordered quickly and easily – from anywhere,<br />

at any time. The portal for German customers was<br />

launched only last year.<br />

In addition, the companie’s experts are currently working<br />

on web-based AI part identification for mobile devices.<br />

HELLER Lens is designed to provide customers with even<br />

faster and more reliable identification of spare parts<br />

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

no. 4, November <strong>2023</strong><br />


machining center<br />

Flexible machine concept successfully improved<br />

Maximum process reliability, more flexibility<br />

and excellent productivity: Liebherr-Verzahntechnik<br />

GmbH has successfully overhauled its gear cutting machine<br />

platform for workpieces with a 0 up to 500 mm.<br />

The new machine generation now provides even more<br />

flexibility. The highlight: easy chamfering during the<br />

machining process is now possible using either ChamferCut<br />

or FlexChamfer.<br />

and FlexChamfer, which chamfers using common end mills<br />

– perfect for small batch sizes. “This means that two chamfering<br />

technologies have been integrated into one machine,”<br />

says Breith, “something that is unique on the market.” An<br />

automatic ringloader transports the workpiece from the main<br />

machining position to the perpendicular chamfering position.<br />

Internal gears can now even be chamfered on the gear<br />

shaping and gear skiving machines.<br />

An overview of the machines on the<br />

redesigned platform: the spectrum of Liebherr gear technology<br />

What is clear when looking at the modern, monolithic design<br />

is that a lot has changed with this new generation. But<br />

the technical improvements in this comprehensive overhaul<br />

are even more remarkable. “In the past few years, we’ve continued<br />

to improve the machine platform for machining workpieces<br />

with a 0 up to 500 mm, optimizing the machine bed,<br />

the chamfering device and the machining head”, explains<br />

Thomas Breith, head of product management for Gear Cutting<br />

Machines at Liebherr-Verzahntechnik GmbH.<br />

Optimized for high performance<br />

The machine bed was completely overhauled. For dry machining,<br />

the machine table, machine column and box guideways<br />

have been lined with stainless steel plates, ensuring improved<br />

chip evacuation. This means that, in particular, the temperature<br />

behavior remains constant, providing greater gear quality<br />

and process stability. The reworked HH240 hob head on<br />

the LC 500 gear hobbing machine with its longer travel ranges<br />

and improved rigidity in its counter bearing guarantees high<br />

performance. Optional add-ons include a swivel-in measuring<br />

probe and a mobile meshing device for centering the tool<br />

into the workpiece.<br />

One of a kind: chamfering during the machining<br />

process with ChamferCut or FlexChamfer<br />

What is unique about the new generation is that an optional<br />

chamfering device can be integrated into the machine, providing<br />

two possibilities for chamfering during the machining<br />

process: the fast and economical ChamferCut process<br />

Longer travel ranges and optimized rigidity also provide<br />

more stability and thus greater process reliability.<br />

Greater user comfort thanks to<br />

improved ergonomics<br />

The user comfort and ergonomics of the machines have also<br />

been optimized. A larger machining chamber, fold-out steps<br />

and glass maintenance doors make it easier to access the machine,<br />

and encased hydraulic units make it quieter. The control<br />

panel with its LHGearTec user interface was improved.<br />

The fixed LHStation monitor unit as well as the LHMobile<br />

handheld terminal, both equipped with a Multi-Touch interface<br />

and context-sensitive user guidance, make it even easier<br />

to use and program the intuitive controls. Although the<br />

monolithic design of the machines makes them seem larger,<br />

their footprint is in fact smaller than that of previous units.<br />

Modular system guarantees exceptional flexibility<br />

For satisfying the requirements of a variety of sectors from<br />

heavy industry to automobiles and other industrial applications,<br />

Liebherr always relies on a modular machine concept.<br />

Breith, “our gear cutting machines are robust, high-quality<br />

and can be individually configured. Different table drives,<br />

machining heads and automation solutions as well as optional<br />

accessories satisfy a wide range of applications. We<br />

were determined to continue this tradition in our new machine<br />

generation.”<br />

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

34 no.4, November <strong>2023</strong>

machining center<br />

New universal<br />

loading system<br />

STUDER S31<br />

with insertLoad loading system<br />

insertLoad at a glance<br />

➤ efficient standard solution<br />

➤ universal use<br />

➤ operation through setup wizard<br />

➤ loading between centers or in a chuck<br />

➤ full integration in machine design<br />

Where customized solutions were previously neces-<br />

sary, the new universal loading system from STUDER<br />

now enables standardized automation for loading and<br />

unloading the S33 and S31.<br />

insertLoad can be used for center distances of up to 1,00 mm<br />

(39.4 inches), thus closing a gap in standardized automation<br />

systems. The workpieces can be up to 100 mm (3.94 inches)<br />

long and weigh 1.5 kg (3.3 lbs) in alternating mode or 5 kg<br />

(11 lbs) in a single mode. The sophisticated design and the<br />

ease of use with the digital setup wizard allow users to configure<br />

this themselves for centers and chucks – no programming<br />

knowledge is required. And insertLoad can handle<br />

workpieces that are stored either vertically or horizontally.<br />

The best combination of standardization<br />

and flexibility<br />

The new STUDER loader combines the advantages of a standardized<br />

system with great flexibility. It handles a wide variety<br />

of parts in terms of geometry, weight, and size; even the<br />

capacity of the drawers and the degree of autonomy can be<br />

adapted based on the needs and requirements. Loading and<br />

unloading is handled by a Fanuc robot, which moves independently<br />

on a linear axis between the loader and the<br />

machine’s work area. Typically, the time without human<br />

operator intervention is between thirty and sixty minutes.<br />

Gripper for workpieces clamped in a chuck<br />

STUDER placed particular emphasis on safety during development.<br />

For example, a loading hatch separates the loading<br />

area of the insertLoad from the working area of the<br />

machine to prevent flame flashback during machining processes<br />

using grinding oil. In addition, the software and a<br />

safety switch ensure that grinding technicians are not endangered<br />

in the event of a deflagration.<br />

Availability for additional machines planned<br />

The insertLoad was presented to the international trade public<br />

for the first time at the world’s leading trade show for<br />

metalworking, EMO. Initially, it will only be available for the<br />

S33 and S31 CNC universal cylindrical grinding machines,<br />

but the availability for other models is in preparation. The<br />

S33 and S31 are ideal grinding solutions for small to large<br />

workpieces in single, small batches and volume production.<br />

Both machines feature distances between centers of 400 to<br />

1,600 mm (15.75 to 63 inches) and a center height of 175 mm<br />

(6.9 inches).<br />

Gripper for shafts clamped between centers<br />

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

no.4, November <strong>2023</strong><br />


machining center<br />

Connecting the art of engineering with<br />

digital know-how<br />

Automotive and supplier industry, rail transport,<br />

aerospace – in these and many other industries, production<br />

processes are changing rapidly and from scratch.<br />

In the spotlight: digital technologies, robotics and artificial<br />

intelligence – they are shaping industrial manufacturing<br />

more and more and make sure that physical<br />

and virtual processes are closely intertwined. Highquality<br />

machine tools and processing centers in combination<br />

with data competence and simulation expertise<br />

are in demand.<br />

3D simulations for more efficient production lines<br />

At the FFG Group booth at EMO, visitors could experience<br />

live at numerous exhibits how mechanical engineering<br />

and digital know-how can be combined to create measurable<br />

added value: maximum flexibility, low costs per part, and<br />

optimal efficiency, as well as energy and resource savings<br />

on the way to climate-neutral manufacturing. “To find the<br />

most effective and economical arrangement of workstations,<br />

machines and robots, we use 3D simulations. With these planning<br />

tools, we can plan assembly and production lines both<br />

efficiently and realistically”, says Dr. Sebastian Schoening,<br />

CEO of FFG Europe & Americas. As a so-called process<br />

twin, the three-dimensional representation delivers accurate<br />

and reliable results and makes production processes<br />

and customer- specific details transparent. A digital product<br />

twin is also created on the basis of the 3D design data – it<br />

visualizes the technical specifications as well as the design of<br />

the individual machines.<br />

A virtual immersion in production planning<br />

The intelligent combination of these two information streams<br />

leads to a digital plant twin: it represents the overall system,<br />

which can be used to implement all planning, changes and<br />

inputs for virtual testing before commissioning. FFG’s experts<br />

literally immerse themselves into production and material<br />

flow planning and can run through a variety of what-if<br />

scenarios. This opens up deep insights into processes, minimizes<br />

investment risks and saves costs. For new product<br />

launches, connected and integrated production systems ensure<br />

manufacturing excellence from day one.<br />

Smart controls reduce CO2 emissions per part<br />

The energy consumption of machines and systems can also<br />

be calculated precisely for different production environments.<br />

There are numerous starting points to reduce the energy<br />

requirements of machine tools. “When it comes to implementing<br />

energy-saving solutions, we see ourselves as frontrunners.<br />

Above all intelligent software control helps to keep<br />

the CO₂ footprint per produced part low and makes the<br />

operation of entire manufacturing systems sustainable," says<br />

Dr. Sebastian Schoening.<br />

further information: www.ffg-ea.com<br />

36 no. 4, November <strong>2023</strong>

Automation and digitalization in<br />

machine tool building<br />

machining center<br />

Doosan Machine Tools becomes DN Solutions.<br />

DN Solutions participated for the first time under<br />

a new name at the world’s largest machine tool trade<br />

fair “EMO <strong>2023</strong>”. The machine tool manufacturer presented<br />

a selection of state-of-the-art machines.<br />

DN Solutions presented 20 machines to the trade public at<br />

close quarters. The exhibits were divided into three categories<br />

and represented high-productivity automation, smart manufacturing,<br />

and advanced 5-axis/composite processing. In the<br />

“Flexible Automation” area visitors experienced the seamless<br />

integration of various solutions for workpiece handling, including<br />

robot, gantry loader and pallet system solutions.<br />

This included the compact turning center (PUMA<br />

DNT2100) equipped with a collaborative robot, the twospindle<br />

horizontal turning center (PUMA TW2600M) integrated<br />

with a gantry loader, the horizontal machining center<br />

(NHP 5000) featuring a rotary pallet system and the compact<br />

5-axis vertical machining center (DVF 4000) with the Automatic<br />

Workpiece Changer (AWC).<br />

In the “Real Digitalization” category, DN Solutions presented<br />

intelligent manufacturing solutions based on userfriendly<br />

technologies for digital transformation. The advantages<br />

of digital twin technology was demonstrated, including<br />

the minimization of error sources through virtual verification<br />

and the reduction of machine set-up times. With the<br />

multi-tasking PUMA SMX3100ST, DN Solutions also exhibited<br />

skiving machining technology using the table turning<br />

function. Additionally several live machining demonstrations<br />

were conducted with the purpose of showcasing the<br />

unique features and characteristics of each machine.<br />

The topic of sustainability also played a major role.<br />

Under the motto “Green Forward” DN Solutions presented<br />

energy-saving systems such as the mist-free solution for oil<br />

mist separation and the power consumption monitoring system<br />

at the trade fair. The mist-free solution offers the particular<br />

advantage of minimizing motor power. This leads to<br />

lower electricity and maintenance costs.<br />

International cooperations<br />

underlined trade fair presence<br />

Another highlight was shown at the Siemens stand. In cooperation<br />

with the German player, the SMX2100ST multitasking<br />

machine has been equipped with SINUMERIK ONE,<br />

Siemens’ CNC system optimized for the digital twin.<br />

further information: www.dn-solutions.com<br />

no. 4, November <strong>2023</strong><br />


machining center<br />

Perform a variety of grinding tasks<br />

in quick succession<br />

Extreme dimensional accuracy, maximum<br />

efficiency – under these specifications,<br />

external cylindrical grinding is<br />

an indispensable process for contract<br />

grinders, medical technology, general me -<br />

chanical engineering and many other industries.<br />

However, especially for smaller<br />

series or prototype production, it is important<br />

to have a grinding solution that<br />

is as universal as it is flexible, and that<br />

canbe retooled and configured in a very<br />

short time.<br />

The graphical dialog<br />

interface is based on<br />

Windows and simplifies<br />

massively the input of<br />

technology parameters<br />

for a given cycle<br />

How can process reliability and accuracy<br />

be guaranteed under these circumstances?<br />

EMAG Weiss provides an answer to this question<br />

with the W 11 CNC cylindrical grinding<br />

machine for workpieces with a 0 of up to<br />

500 mm and a length of up to 1,500 mm. The<br />

entire technology is designed to perform a<br />

wide range of machining requirements in<br />

rapid changeover.<br />

The initial situation is as familiar as it is<br />

challenging: many users in industry machine<br />

shafts and other rotationally symmetrical<br />

components are using a final cylindrical<br />

grinding process. Subsequently the surfaces<br />

exhibit exceptional precision and quality in<br />

the µ range. However, smaller quantities or<br />

prototypes thus become a special task, because<br />

each machine set-up takes a relatively<br />

long time – and, of course every error must be<br />

avoided. In this context the W 11 CNC from<br />

EMAG Weiss is a special solution: a CNC-supported<br />

external-internal cylindrical grinding<br />

machine, which can also be operated manually<br />

or be equipped flexibly with different grinding<br />

wheels. For example when machining<br />

with one wheel from the side, parallel one can<br />

use machining with two external grinding<br />

wheels or the combination of internal and external<br />

grinding wheels (as well as many other<br />

variants). Also there are few restrictions on<br />

the type of wheels – 0 of 400 or 500 mm and<br />

widths of 10 to 120 mm are possible.<br />

Intuitive operation facilitates processes<br />

The aforementioned flexibility is ensured by<br />

a whole bundle of measures. For example the<br />

basic control system already contains all common<br />

grinding cycles. The operator calls them<br />

up via an easy-to-understand dialog interface<br />

Optionally the machine is equipped with automatic doors,<br />

making the interior easier accessible<br />

The external-internal cylindrical grinding machine can also<br />

be operated manually<br />

38 no. 4, November <strong>2023</strong>

machining center<br />

and enters the required dimensions via<br />

fields. In addition automatic dressing, grinding<br />

of several diameters, saving of grinding<br />

sequences, contour dressing and taper grinding<br />

in path mode are all easily possible with<br />

the CNC control. But also the following always<br />

applies here: anyone who wants to carry<br />

out the process manually can do so at any<br />

time, bypassing the CNC control. In any case,<br />

the good accessibility of the machine facilitates<br />

the operator’s work.<br />

At the same time the mechatronic details<br />

around the workhead, tailstock and grinding<br />

head of the W 11 CNC score points when it<br />

comes to executing fast changeover processes:<br />

➤ for example, the spindle mount (with<br />

MK4, MK5 or MK6 adapter) has a<br />

precision bearing, and the speed can<br />

be continuously adjusted from 1 to up<br />

to 650 rpm – even 2,000 rpm is possible<br />

as an option<br />

➤ the tailstock (MK4) can be operated<br />

manually and pneumatically by foot<br />

switch; the quill holder with a stroke of<br />

45 mm enables loading between centers<br />

up to a weight of 250 kg; optionally the<br />

machine can also be equipped with<br />

an NC tailstock with a travel of up to<br />

300 mm for a maximum workpiece<br />

weight of 350 kg; in addition manual<br />

cylinder correction is also another option<br />

➤ also standard (and important for<br />

flexibility) is a direct-drive B-torque<br />

axis for stepless swiveling and positioning<br />

of the grinding head with a resolution<br />

of just 0.0001 mm<br />

➤ last but not least, optional in-process<br />

measurement based on Marposs<br />

measurement control is available<br />

Changeover processes<br />

in just five minutes<br />

The effect of this combination of high-tech<br />

equipment and intuitive control is demonstrated<br />

by various practical examples, as the<br />

machine is currently in use in many facilities.<br />

For example the experts at EMAG Weiss<br />

estimate that many changeover processes<br />

just take five minutes. This example shows its<br />

value in the production of part families with<br />

multiple component changes, leading to enormous<br />

time savings over a shift or a week – and<br />

always against the background of enormous<br />

dimensional accuracy with tolerances of just<br />

0.001 mm. Additionally users have a futureproof<br />

solution that can handle a wide range<br />

of tasks.<br />

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

Flexibility is the key: the W 11 CNC can be operated<br />

with a wide range of grinding wheel arrangements<br />

Workpieces with a 0 of up to 500 mm and a length of up to 1,500 mm<br />

can be finished in quick succession<br />

The W 11 CNC cylindrical grinding machine is predestined for single-part and<br />

prototype manufacture: it is also used for small series and sample production<br />

no. 4, November <strong>2023</strong><br />


machining center<br />

ULTRA technology enables<br />

high quality production of small and micro tools<br />

ANCA, the grinding technology experts, presented<br />

two new machines at EMO. The MicroX ULTRA sixaxes<br />

machine is designed to meet the demands in a<br />

micro tool volume production environment, the machine<br />

has the nanometer control and optimized kinematics;<br />

fast wheel change, tool setup and an uninterrupted<br />

tool grinding to offer superior micro tool<br />

grinding. Micro tools are an important and growing<br />

industry, servicing 3C, medical, automotive, watchmaking<br />

and jewellery industries.<br />

Pat Boland, ANCA co-founder said: “The MicroX propels<br />

ANCA products into an important market segment:<br />

microtools. Leveraging ANCA’s cutting-edge ULTRA grinding<br />

technology and MicroX kinematics, the intelligent technology<br />

offers exceptional precision, unwavering stability, and<br />

heightened productivity upon tools spanning a 0 spectrum<br />

from 6 mm to a mere 0.05 mm.”<br />

The ULTRA technology which is applied in the MicroX,<br />

has been introduced by ANCA last year on their MX machine<br />

series. ANCA’s vertical integration and 50 years of partnership<br />

with cutting tool makers means that this machine combines<br />

industry knowledge, market needs and ground breaking<br />

technologies to offer the market advanced solutions. New<br />

software, hardware and design features significantly improve<br />

surface finish, accuracy and controlled runout, ensuring<br />

batch consistency from the first ground tool to the last.<br />

In addition to the MX, ANCA presented the renowned<br />

universal FX series as an ULTRA version. “The FX7 ULTRA<br />

introduces cutting-edge technologies that revolutionize precision<br />

grinding for small tools down to 0 0.1 mm. If you produce<br />

tools such as ballnose, corner radius endmills and complex<br />

or intricate profile tools, then this machine is for you,”<br />

says Darren Fox, ANCA product manager.<br />

The FX7 ULTRA<br />

is the go-to<br />

solution for<br />

precision<br />

grinding in<br />

industries that<br />

rely on small<br />

tools<br />

FX7 ULTRA offers<br />

unparalleled accuracy<br />

for small tools down<br />

to 0.1 mm<br />

The ULTRA package<br />

➢ one nanometer control system<br />

➢ new servo control algorithm for smooth motion<br />

➢ system and mechanical upgrades enhance<br />

stiffness and rigidity<br />

➢ in-process measuring, balancing and runout<br />

compensation for consistent accuracy<br />

➢ Motor Temperature Control (MTC) –<br />

ANCA’s patented innovation<br />

➢ specialist training support from our engineering<br />

experts on how to grind perfect cutting tools<br />

As a dedicated micro tool grinding machine, the MicroX<br />

ULTRA brings along some further features, such as its optimized<br />

linear axes travel with ballnose grinding wheel point.<br />

The C-axis refers to the wheel swivel axis centerline, which is<br />

aligned with the wheel’s 9 o’clock grind point. This specific<br />

design is critical in the grinding of ballnose, corner radius and<br />

profile tools. In the case of a ballnose tool, the X and Y interpolations<br />

during the grinding process will be nearly equal<br />

to the radius of the ballnose tool. Apart from the optimized<br />

axes travel to grind tools to micrometer sizes, the developers<br />

introduced a fast tool setup change including wheel change,<br />

fast wheel change and access to up to 8 grinding wheels, and<br />

uninterrupted continuous micro tool production.<br />

In a volume production setting, micro tools are manufactured<br />

using an uninterrupted continuous loading system.<br />

This system allows for the removal of a pallet containing<br />

ground tools and the seamless loading of a pallet with blanks<br />

into the process, all without the need to halt the grinder.<br />

With a 0 of D 3 mm and the use of three full pallets, the production<br />

capacity amounts to 2,520 tools. However, the most<br />

significant advantage of this added feature is that it unlocks<br />

the potential for an unlimited production capacity.<br />

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

40 no. 4, November <strong>2023</strong>

Surface quality and removal rate doubled<br />

Laser machining center Femto E3 becomes more powerful<br />

machining center<br />

In 2020 Kern launched the first ultra-short pulse<br />

laser center Femto E3. With the latest developments –<br />

especially in the case of process parameters – the<br />

engineers from Kern achieved an essential increase in<br />

productivity.<br />

The manufacturing of carbide press punches, which are used<br />

to produce inserts and other small parts, received an enormous<br />

boost in terms of cost-effectiveness and productivity<br />

with the Kern Femto E3 around three years ago. On the one<br />

hand there are no tool costs when working with the femtosecond<br />

laser. On the other hand time needed for manufacturing<br />

is far less than time needed for erosion and milling.<br />

With a lot of know-how and intense engineering Kern now<br />

succeeded, after only three years, to optimize parameters like<br />

pulse power, pulse time and scan speed so that the manufacturing<br />

of carbide press punches becomes even more productive.<br />

No matter for what application, the results are a significantly<br />

improved surface quality and removal rate.<br />

The single values could be doubled and were proved by<br />

orders from customers and demo parts, as could be seen at<br />

EMO <strong>2023</strong>. Quirin Herterich, responsible for sales of laser<br />

technologies at Kern provides the numbers: “Up to now we<br />

achieved a removal rate of around one cubic millimeter per<br />

minute with tungsten carbide press punches, now we are constantly<br />

at two cubic millimeters per minute.” Equally interesting<br />

are the improvements in surface quality achieved by<br />

Kern – from the previous Ra = 0.2 µm to now Ra = 0.1 µm. This<br />

means that the final polishing can be shortened significantly,<br />

which has a correspondingly positive effect on the overall<br />

running time of the parts.<br />

The strong Kern: Quirin Herterich, responsible for sales of laser<br />

technology; Stefan Kletzenbauer, laser processing developer and<br />

Daniel Asam, laser processing development manager (l. to r.)<br />

This small sample part<br />

shows the high performance<br />

of the Kern Femto E 3<br />

Energy efficient, reliable and easy automation<br />

Regarding cost-effectiveness, Kern’s ultra-short pulse laser<br />

center scores in many ways, like no costs for tools. Additionally<br />

lower energy consumption compared to other technologies,<br />

because of the very economical laser source with an output<br />

of 20 W. The simple operation contributes significantly to<br />

process reliability and good automation. Ultimately the designer<br />

does most of the work by creating the 3D CAD data. At<br />

the end he converts this into a so-called negative model and<br />

transfers it to the Kern Femto E3. The machine operator then<br />

only has to activate the material-dependent parameters, enter<br />

the number of parts required and start the program. The machine<br />

does everything else – 100 % error-free.<br />

When is it worth purchasing a Femto E3?<br />

According to Quirin Herterich, there is no general answer<br />

as to who can benefit from purchasing the innovative femto -<br />

laser center, since many different parameters have to be taken<br />

into account: “We always discuss options together with the<br />

potential customer,” says Herterich, but still gives a thumbnail:<br />

“As a rule, the purchase is worthwhile if the machine<br />

is used for around 2,000 hours per year, which roughly corresponds<br />

to continuous single-shift operation.” During this<br />

time, depending on the topography, around 500 to 1,000<br />

punches can be produced.<br />

As an alternative to purchasing the Femto E3, Kern offers to<br />

manufacture it to order. Meaning that even smaller quantities<br />

up to batch size 1 can be produced economically. This applies<br />

for example if prototype parts have to be produced in several<br />

loops. Then all you have to do is adapt the CAD data and convert<br />

it to the negative model. The new part can now be created.<br />

“Minimal effort compared to other manufacturing processes,”<br />

confirms Quirin Herterich.<br />

The Kern laser technology expert is certain that the Femto<br />

E3 will soon open up additional fields of application. “We<br />

now use processing software that allows very fine texturing<br />

to be introduced onto small parts.” This means that lines,<br />

troughs, or free shapes with just 10 µm or 20 µm can be created<br />

into any surface according to customer requirements.<br />

There are many applications for this.<br />

further information: www.kern-microtechnik.com<br />

no. 4, November <strong>2023</strong><br />


machining center<br />

A brand of its very own<br />

At EMO <strong>2023</strong> CHIRON Group interpreted the exhibition<br />

motto “Innovate Manufacturing” in its own<br />

way and presented its comprehensive portfolio for the<br />

first time under the globally uniform CHIRON Group<br />

brand. This included machine innovations live under<br />

chip, a highly variable automation solution and innovative<br />

services.<br />

Machining highlights in live operation<br />

In recent months the CHIRON Group has continued its<br />

product offensive and presented five machining centers in<br />

live operation. An absolute crowd-puller was the DZ 22 S mill<br />

turn for flexible, piece-cost-optimized production of small to<br />

medium batches, for example of e-motor housings. The next<br />

generation of the 15 Series celebrated its premiere with new<br />

rotary tables developed in-house and the intuitive Siemens<br />

SINUMERIK ONE control. On show was the DZ 15 W with<br />

180 ° swivel table, two separate workspaces and workpiece<br />

changer for efficient milling of large batches. Customers from<br />

the medical and precision technology sectors were able to experience<br />

highly dynamic and autonomous micromachining<br />

in the smallest of spaces on the intelligent combination of the<br />

Micro5 machining center and the Feed5 handling system.<br />

Also on the topic of automation, an innovation could be<br />

seen live: the VariocellMove for intelligent workpiece handling;<br />

the compact robotic cell with inclined pallet system<br />

can be flexibly combined with milling and mill-turning centers<br />

from the CHIRON Group to form a productive unit.<br />

Innovative services<br />

The experts from the CHIRON Group Service presented the<br />

new customer portal myCHIRON with an e-shop for fast ordering<br />

of spare parts and a new service: Repair, refurbishment<br />

and optimization of motor spindles. An innovative offer<br />

– already available in Germany, Austria and Switzerland –<br />

makes it easy to get started in quality manufacturing:<br />

PerformanceFinance, a complete machine financing package<br />

including cyclical condition monitoring and comprehensive<br />

services. Those who already have a machining center<br />

from the CHIRON Group in operation were able to obtain<br />

information about an individual refurbishment. Such<br />

an “upgrade” makes an existing machining center fit for new<br />

manufacturing tasks and not only saves financial resources,<br />

but also protects the environment.<br />

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

Gear center for use in the prototype sector<br />

up to large series production<br />

The KNG 350 flex is based on a compact, stand-optimized<br />

machine concept for use in the prototype area<br />

to large-scale production of gears up to Ø 350 mm. An<br />

optional diameter extension is available.<br />

Available machining processes are generating and profile<br />

grinding, depending on the application with dressable corundum<br />

or non-dressable CBN tools. A unique selling point is<br />

polishing as a single technology, for example to finish gears<br />

after shot peening.<br />

The performance-optimized grinding spindle with counter<br />

bearings allows cutting speeds of up to 100 m/s and is<br />

designed for the use of large grinding worms with widths of<br />

up to 200 mm. This allows an efficient realization, especially<br />

when machining of components with large modules and<br />

using 2-sector worms for fine grinding or polishing applications.<br />

Auxiliary spindles can be adapted directly on the tool<br />

spindle using the new quick-change interface. Due to the use<br />

of auxiliary spindles, very small grinding wheels with the<br />

minimum root circle of the gear to be grind, can be applied.<br />

The integrated reduction stage enables a cutting speed of up<br />

to 50 m/s even with a grinding wheel 0 30 mm.<br />

A reduction in set-up times is also achieved through the<br />

use of intelligent components (smart tooling). From manual<br />

loading, via a simple pallet conveyor, to a comprehensive<br />

automation solution, the concept offers full flexibility in loading<br />

the components. The functional and ergonomic machine<br />

design paired with the innovative user-friendly interface KN<br />

grind supports the user during set-up and optimization of<br />

grinding projects.<br />

Process monitoring, part tracing and inline quality assurance<br />

are available as an integral component for an industry<br />

4.0 capable processing machine. This gear center impresses<br />

not only with its excellent design (iF Design AWARD), but<br />

also with its continuous further development with a view to<br />

energy efficiency. The hydraulic functions, which are reduced<br />

to a minimum, are covered by a controlled pump unit, and<br />

pneumatic functions are largely replaced by electric drives.<br />

The consideration of the complete life cycle of the machine<br />

shows, the entire CO 2<br />

equivalent of the machine, is reduced<br />

by changing the machine bed from cast iron to polymer<br />

concrete.<br />

further information: www.kapp-niles.com<br />

42 no.4, November <strong>2023</strong>

machining center<br />

Reducing throughput times, eliminating operations<br />

with no added value and optimizing processes<br />

The LEAN philosophy has been deeply ingrained<br />

within Rollomatic for numerous years, forming an integral<br />

part of the corporate culture and permeating<br />

the design of all products. Reducing throughput times,<br />

eliminating operations with no added value and optimizing<br />

processes are just some of the challenges facing<br />

our customers. The GRINDSMART® 660XW, a new<br />

model designed by Rollomatic, is a perfect illustration<br />

of this. By combining it with the GRINDSMART®<br />

830XW model, Rollomatic is able to offer grinding<br />

solutions covering the entire diameter range of micro<br />

and macro tools.<br />

The solution for high-performance rotary tools<br />

with 0 0.1 to 12.7 mm<br />

Complete tool grinding solutions, including cylindrical<br />

grinding in a single clamping operation. The ultra-compact<br />

GRINDSMART® 660XW 6-axis high-precision grinding<br />

center has been designed to produce rotary cutting tools with<br />

0 ranging from 0.1 to 12.7 mm, and includes a high-capacity<br />

tool loader and ultra-fast wheel changer. Its unique and<br />

innovative design provides superior accuracy and reliability.<br />

This machine has been designed for the production of large<br />

or small series of high-performance cutting tools.<br />

6-axis kinematics<br />

The machine features 4 linear and 2 rotary axes. The unique<br />

aspect is the workhead which is mounted on a CNC linear<br />

axis. With this feature, the tool grinding and the well-known<br />

Rollomatic peel grinding process are combined together into<br />

a single machine model. The benefit of the traveling workhead<br />

for peel grinding operations is that the grinding wheel<br />

is always on top of the steady rest while the workhead axis<br />

is pushing the tool through the grinding wheel, providing<br />

excellent process stability. This CNC workhead axis is also<br />

a great benefit for drill applications, as an innovative steady<br />

rest design combines optimal tool support for fluting and for<br />

pointing.<br />

Advantages<br />

• the Lean Grinding Process provides significant<br />

reduction in cycle times<br />

• integrated ultra-compact tool loader, 1360-part capacity<br />

• 6-position high-speed wheel changer<br />

• exceptionally short set-up times with the help<br />

of the Smart Setup Assistant<br />

• low energy consumption<br />

The solution for high-performance rotary tools<br />

up to 0 32 mm<br />

The GRINDSMART®830XW is designed for both large and<br />

small production runs and features six simultaneously interpolated<br />

axes, with an innovative combination of hydrostatic<br />

technology and linear motors. This feature, which is unique<br />

GrindSmart 830XW<br />

in the cutting tool industry, provides very high rigidity and<br />

dampens vibrations that may occur during machining, increasing<br />

the life of the wheels and guaranteeing unbeatable<br />

surface finishes, giving users a real competitive edge. Autonomy<br />

is another advantage, allowing unattended produc tion<br />

over an extended period without human intervention.<br />

Advantages<br />

• maintains constant grinding point for relief operations<br />

on ballnose, radii and form tools<br />

• unlimited flexibility of movement due to the 6 th axis<br />

design and the total symmetry of the spindle axis<br />

• 10-pallet capacity, up to 4,500 blanks<br />

• wheel pack changeover under 11 s<br />

• mirror surface finishes<br />

• razor sharp cutting edges<br />

• geometric accuracy below 0.003 mm<br />

• dimensional repeatability in production below 0.01 mm<br />

Automatic measurement and compensation system<br />

VIRTUALGRIND®PRO the innovative and powerful programming<br />

software that comes with GrindSmart® CNC<br />

grinding machines. This software platform is used across<br />

the entire range of Rollomatic machines and provides the<br />

user with the ability to program and grind various types of<br />

cutting tools, whether they are standard or complex.<br />

It is equipped with highly valuable features, including the<br />

Smart 3D Simulator. This function replicates the programmed<br />

tool in a 3D simulation and showcases machine animations<br />

prior to the grinding process. This not only minimizes setup<br />

time but also mitigates the risk of potential collisions. Further<br />

built-in elements are the Smart Setup Assistant, designed<br />

to achieve the first ground tool within specified tolerances,<br />

and the In-Process Measurement feature, which conducts<br />

laser or touch measurements to apply necessary compensations,<br />

ensuring reliable and unattended production.<br />

further information: www.rollomatic.ch<br />

no. 4, November <strong>2023</strong><br />


components<br />

Aerotech brings movement to the<br />

automation process<br />

With around 50,000 trade visitors<br />

and almost 1,000 exhibitors, the SPS<br />

in Nuremberg is one of the world’s top<br />

events for control and automation technology.<br />

Aerotech will also be presenting<br />

its high-precision motion control and<br />

positioning solutions November, 14 – 16,<br />

<strong>2023</strong> (hall 3, booth 251).<br />

At the exhibition stand components as well as<br />

the motion control platform Automation1 will<br />

be demonstrated as integrative components<br />

in the automation process. Together with the<br />

current Automation1 Release 2.5, the digital<br />

PWM drives XA4 and iXA4 will be presented<br />

to the visitors for the first time. In addition,<br />

a gantry system with a rotating bridge will<br />

be presented that exemplifies the possibilities<br />

of coordinated movements and transformations<br />

of Automation1.<br />

“The motto of this year’s SPS, ‘Bringing<br />

Automation to Life’, is something that I would<br />

like to make a little more precise for Aerotech<br />

‘Bringing Automation to Motion’”, says Simon<br />

Smith, looking forward to the Nuremberg<br />

trade fair. The European director at Aerotech<br />

has good reason to do so, because his topics<br />

fit perfectly into the trade fair concept, from<br />

control components to automation.<br />

Simon Smith: “For Aerotech I’d like to change this year’s SPS motto from<br />

‘Bringing Automation to Life’ to ‘Bringing Automation to Motion’ ”<br />

Simon Smith specifies: “As a manufacturer of automation systems we support<br />

manufacturing companies in optimally automating their processes<br />

with our precision motion components.” Aerotech has developed its motion<br />

control technology into the Automation1 motion control platform. This<br />

platform can control almost any peripheral device, from linear motion to<br />

handling robots to measuring systems. Simon Smith emphasises the flexibility<br />

of the motion control platform: “Users can use Automation1 to support<br />

their automation process beyond pure motion control. If the process changes<br />

and new peripheral components are added, they can be easily integrated into<br />

Aerotech has been strengthening its commitment<br />

to automation for years and is also<br />

positioning itself as a system supplier for highquality<br />

motion control and positioning systems<br />

as well as complete automation solutions<br />

for the SPS. For over 50 years the company has<br />

offered a wide range of components, such as<br />

motors, drives, controlers and positioning tables,<br />

the majority of which are manu factured<br />

in-house. These components are used in a<br />

wide range of applications, from electronics<br />

manufacturing to medical technology and<br />

additive manufacturing.<br />

But Aerotech goes a step further by developing<br />

integrated systems that provide near-turnkey<br />

solutions for automated processes. These<br />

systems include not only the precision motion<br />

control components manufactured in-house,<br />

including the control platform, but also comprehensive<br />

automation integration for part<br />

handling, process instrumentation, safety and<br />

custom software.<br />

Camera module integrated into motion control: a camera recording is displayed<br />

as a live video feed with optional crosshairs, the acquisition and display of<br />

images and axis positions directly on the screen of the control platform<br />

44 no. 4, November <strong>2023</strong>

components<br />

Block diagram of the decoupling control<br />

Automation1 without having to purchase new control software.<br />

We will be happy to demonstrate how this works to<br />

trade visitors at the SPS.”<br />

Automation1 with more and more functions<br />

The latest version 2.5 of the Automation1 motion control<br />

platform comes with a wealth of new features that significantly<br />

improve research, development and industrial automation.<br />

Simon Smith comments: “With these additional functions<br />

and the user-friendly interface we are once again demonstrating<br />

our expertise as a leading provider of precision<br />

motion controls for the most diverse automation solutions.”<br />

position of the logical linear axis (R) is thus simply the average<br />

of the two physical actuator positions. The logical rotational<br />

position (Theta) is the difference between the two actuator<br />

positions divided by the distance between the two actuators.”<br />

In an H-bridge gantry, the logical rotational axis results<br />

in a yaw movement of the gantry. Decoupling control is also<br />

referred to as yaw control. The position control loops act on<br />

the logical linear axis (R) and the logical yaw axis (Theta) and<br />

not on the physical axes. (see the block diagram)<br />

Galvo scanner calibration is now easier. Users can change<br />

calibration and power correction files for galvo laser scanners<br />

without resetting the control. Support for higher derivative<br />

feedforward control has been improved and laser scan head<br />

drives now automatically interpolate feedrate.<br />

Gantry and encoder functions also have been enhanced.<br />

There is a new wizard for homing gantries and users can output<br />

quadrature or clock and direction signals from a specific<br />

encoder port. A checklist module makes Gantrys setup easier,<br />

and Gantry configuration has been optimized.<br />

Another interesting option is the integrated camera module<br />

in the MachineApp from Automation1. Allowing users to<br />

monitor the entire associated automation process live, in addition<br />

to motion control. To prevent that everybody can see<br />

into the production via camera, specific MachineApps can be<br />

adapted directly in the control platform via an extended HMI<br />

interface (Human Machine Interface) and access can be restricted<br />

based on user rights or group membership.<br />

Motion system unrestrictedly configurable<br />

The gantry system shown on the stand consists of two linear<br />

actuators with a flexible joint on each axis, connected to a<br />

plate as a bridge. This demonstrates our gantry configuration<br />

capability by allowing the actuators to rotate the entire gantry<br />

bridge in differential mode. The system is controlled with<br />

Aerotech’s Automation1 controller. “We use our new gantry<br />

control with Automation1 to demonstrate how decoupling<br />

control of the axes is made possible,” explains Simon Smith.<br />

“In doing so the decoupling method performs a coordinate<br />

transformation and converts the two physical linear axes into<br />

a logical linear axis (R) and a logical rotary axis (Theta). The<br />

You can also control a rotational movement (yaw)<br />

on the yaw axis (Theta) via the decoupling control<br />

when working with a flexible gantry<br />

The trade fair demo shows the high flexibility of the Automation1<br />

to control the Theta rotary axis, which can be used<br />

for small alignments of the bridge and thus contributes to the<br />

flexibility of the gantry system.<br />

Simon Smith adds: “We will also present the auxiliary func -<br />

tions of Automation1 that allow the user to set up the control<br />

very easily and quickly.” One example of these auxiliary<br />

functions, he says, is the setup of the homing routine, where<br />

the home position can be automatically set to the center of<br />

the travel range and the system calculates this automatically<br />

after moving from limit to limit. This saves the user a lot of<br />

time when installing and setting up the motion solution.<br />

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

no. 4, November <strong>2023</strong><br />


components<br />

Efficient tool handling by hand<br />

New tool separator for tools up to 2.5 tons<br />

Goodbye chisel and hammer and hello to the new<br />

kind of manual tool handling! RUD Tecdos TSB (short<br />

for Tool Separator Bench) is the name of the latest<br />

innovation from RUD Ketten Rieger & Dietz GmbH<br />

und Co. KG located in Aalen, Germany. With the RUD<br />

Tecdos TSB opening and closing tools weighing up to<br />

2.5 tons is now particularly quick and simple, and can<br />

be done simply by hand.<br />

That’s right, entirely without additional gripping tools. Cool<br />

for the workflow in the injection moulding industry: the<br />

opened mould halves can be cleaned and serviced directly<br />

on the tool separator – thanks to the 360 ° rotation function.<br />

RUD Tecdos TSB is already the fourth RUD innovation for<br />

efficient tool handling. The specialist is thus further expanding<br />

its RUD Mould Handling Solutions division and once<br />

again establishing itself as a solution provider for integrated<br />

mould handling.<br />

“Moulds and tools weighing up to 2.5 tons present many<br />

users in the injection moulding industry with a dilemma:<br />

they are too heavy for manual opening and closing, but the<br />

use of larger auxiliary equipment is not efficient either. With<br />

the Tecdos TSB we offer an adequate solution for efficient<br />

and safe opening and closing,” explains Anne Kühling, product<br />

manager in the Conveyor & Drive division at RUD Ketten<br />

Rieger & Dietz GmbH & Co.<br />

RUD Tecdos TSB for tools up to 2.5 tons<br />

The new Tecdos TSB tool separator facilitates manually guided<br />

and controlled opening and closing, entirely without the use<br />

of gripping tools or additional electrical, pneumatic, or hydraulic<br />

energy. Light and medium-weight moulds can be<br />

opened and closed easily, quickly, safely, and ergonomically<br />

by hand, using only the two sliding plates. Time-consuming<br />

disassembly of hoses, connections and other components is<br />

not necessary.<br />

The Tecdos TSB is available in two versions with different<br />

sized plates of 60 x 30 cm or 80 x 40 cm. Thanks to the low<br />

working surface of 31 cm, working on the new tool separator<br />

is particularly ergonomic.<br />

Optimized workflow and top efficiency<br />

The sliding plates have a special feature in store: they are not<br />

only movable, for opening and closing the moulds and tools,<br />

but can also be rotated by 360 °. This allows the opened mould<br />

halves to be rotated vertically around their own axis – for easy<br />

inspection, cleaning, and maintenance directly on the work<br />

surface of the mould opener. By means of a locking mechanism<br />

the plates can be fixed in place for maintaining the tool.<br />

46 no. 4, November <strong>2023</strong>

components<br />

Tecdos TSB can be operated simply, safely, and quickly<br />

by just one person. “With our latest innovation, we not only<br />

shorten handling times, but also the operating time of the<br />

employees for a doubly optimized process in tool handling,”<br />

emphasises Kühling. Thanks to its low weight and compact<br />

dimensions, the new Tecdos TSB can be used flexibly<br />

throughout the factory.<br />

Mould handling solutions<br />

RUD offers the right solution for every stage of work in tool<br />

handling. The Tecdos TM is simply made for the maintenance<br />

and repair of moulds and tools up to 64 tons. It turns and rotates<br />

tools and moulds weighing several tons – and all within<br />

a minute. The Tecdos TS tool separator opens and closes<br />

injection moulding, stamping and forming tools weighing up<br />

to 10 tons in just a few seconds. The Tecdos TS requires a maximum<br />

of five minutes for the entire opening process, thereby<br />

revolutionising processes in production, maintenance and<br />

repair.<br />

Like the new Tecdos TSB, the Tecdos TMB industrial workbench<br />

is designed for tools and moulds weighing up to 2.5<br />

tons. With the 2-in-1 combination of industrial workbench<br />

and turnover device, light and medium weight injection<br />

moulds can not only be turned efficiently and safely, but also<br />

serviced directly on site. “Together with our Tecdos TMB,<br />

our new Tecdos TSB offers an ideal combination of tool turner<br />

and tool separator,” says Kühling.<br />

Process optimisation and occupational safety:<br />

the demand is high<br />

When handling moulds and tools weighing several tons, or<br />

lighter ones, a lot can be gained by working efficiently and<br />

safely, especially in maintenance and servicing. It not only<br />

saves time and costs, but also pays into the occupational safety<br />

of the employees and protects the infrastructure in the<br />

companies.<br />

RUD has witnessed in recent years how great the need for<br />

process optimisation and occupational safety is, especially<br />

in the injection moulding industry. “Ten years ago we developed<br />

our first innovation, the Tecdos TM turning table.<br />

Our other solutions following within the last three years. For<br />

all four developments – Tecdos TM, Tecdos TS, Tecdos TMB<br />

and most recently Tecdos TSB – the impetus came directly<br />

from the market,” clarifies Kühling. “For us it is therefore<br />

only logical to focus our Mould Handling Solutions division<br />

even more strongly and to expand it further”.<br />

further information: www.moldhandling.rud.com<br />

New standard clamping devices<br />

EMUGE adds the EvoGrip centering vises and the<br />

EvoPoint zero-point system to its product range. The<br />

new product category complements the portfolio of<br />

customized solutions for special applications with<br />

standard clamping devices for universal applications.<br />

The EvoGrip centering vises are manually operated direct<br />

clamping devices that clamp the workpiece centrically.<br />

They convince with high clamping forces up to 75 kN combined<br />

with high accuracy. The compact design compared to<br />

the possible workpiece size offers ideal accessibility and allows<br />

the use of short tools for reduced vibrations and higher<br />

cutting values. Clamping devices of this type can be used universally<br />

thanks to the compact design. Geometrically optimized<br />

guidings minimize spreading of the clamping jaws.<br />

The centering vises are designed for automated part and<br />

handling of clamping equipment.<br />

EvoPoint group<br />

EvoGrip<br />

The combination with the EvoPoint zero-point system enables<br />

a modular, very lean system design and the reduction<br />

of set-up times by up to 80 %. Flexible adaptation systems<br />

are available for existing zero-point systems, machine<br />

tables, swivel brackets, cubes and pyramids. The centering<br />

vises can be converted accordingly for clamping large parts.<br />

The new clamping devices are also available in pneumatic or<br />

hydraulic versions. They can also be customized for automation<br />

solutions.<br />

further information: www.emuge-franken.com<br />

no.4, November <strong>2023</strong><br />


components<br />

Door opener to hydraulic expansion technology<br />

The TENDO Silver stationary toolholder is the ideal introduction to<br />

hydraulic expansion technology and offers an excellent price/performance ratio<br />

At EMO <strong>2023</strong>, SCHUNK presented a new toolholder<br />

– the TENDO Silver. It offers the perfect introduction<br />

to tool clamping using hydraulic expansion technology<br />

and scores as a precision all-rounder.<br />

Since a long time users in metalworking have been won over<br />

by the benefits of hydraulic expansion technology in toolholders:<br />

tools are clamped via a hydraulic mechanism where,<br />

on inserting a screw, the internal pressure medium is compressed<br />

and the expansion sleeve elastically deformed. This<br />

way the tool shank is tightly enclosed. The high tension ensures<br />

absolutely secure holding of the tool and precise runout<br />

accuracy of less than 0.003 mm. The outcome of this technology<br />

is optimum workpiece surfaces, avoidance of micro<br />

chipping, protection of the machine spindle and a longer<br />

tool service life. The technological trick is the inner oil cushion<br />

which is highly effective in damping vibrations that occur<br />

during machining. Hydraulic expansion technology is also<br />

far superior to other technologies in terms of sustainability<br />

since it is long-lasting, energy-saving and resource-conserving<br />

in use. The TENDO Silver from SCHUNK’s economy<br />

segment provides users with an all-rounder which, in addition<br />

to its technological advantages, is also highly impressive<br />

due to its outstanding price-performance ratio.<br />

Low-cost entry to hydraulic expansion technology<br />

As an inventor and market leader in the field of hydraulic expansion<br />

technology, SCHUNK has now acquired 40 years of<br />

experience in this technology. Application-specific, differentiated<br />

segmentation of toolholders means customers receive<br />

appropriate hydraulic expansion toolholders according to<br />

their application and requirements. The goal is economical,<br />

efficient and resource-saving machining of parts, which users<br />

of the TENDO series have appreciated for decades now. The<br />

toolholders come finely balanced as standard and are suitable<br />

for high speeds. The tool shanks can be clamped directly into<br />

the toolholder – making the TENDO series, with its micrometer-accurate<br />

tool changes in seconds, a genuine hit. Users<br />

thus save on set-up time and can dispense with additional<br />

peripheral equipment. They benefit from a high degree of<br />

flexibility since, in addition to direct clamping, clamping of<br />

different diameters with slotted or coolant-proof intermediate<br />

sleeves is also possible. The permanent precision runout<br />

accuracy and effective vibration damping ensure metalworkers<br />

a long tool service life and thus cost savings, because<br />

frequent regrinding or new procurement is no longer<br />

necessary.<br />

The TENDO Silver completes the toolholder family in the<br />

economy segment as a precision all-rounder that is compatible<br />

with all machine tool spindles. With its polished surface,<br />

the hydraulic expansion toolholder in DIN contour<br />

is dirt and rust repellent and is available in eight different<br />

interfaces.<br />

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

48 no. 4, November <strong>2023</strong>

components<br />

Tool management made easy<br />

As a world premiere, the HAIMER<br />

Hybrid Chuck was presented exclusively<br />

at EMO. This new and patented technology<br />

combines the advantages of two<br />

clamping worlds – the vibration-damping<br />

properties of a hydraulic chuck with<br />

those of a high-precision, high-performance<br />

shrink fit chuck.<br />

The new Micro Collet Chuck, which was also<br />

making its debut at EMO, is suitable for shank<br />

diameters from 1 mm and meets the customer’s<br />

requirement for maximum runout<br />

accuracy combined with the simplest possible<br />

handling.<br />

New software for shrink fit,<br />

balancing and presetting machines<br />

In the future all HAIMER shrink fit, balancing<br />

and presetting machines will receive a<br />

new software version that includes a bidirectional<br />

interface that can be connected to the<br />

new Tool Room Manager (TRM). This new<br />

software monitors the online status of all<br />

devices in the tool room, documents the<br />

processes and monitors compliance with the<br />

specified tolerances.<br />

An optional OPC-UA interface, client or<br />

MQTT Connect interface standardizes access<br />

to machines, devices and other systems<br />

and enables manufacturer-independent data<br />

exchange.<br />

On the Tool Dynamic balancing machine<br />

the new software opens the door to automatic<br />

indexing also. For this purpose a small gripper<br />

is integrated in the new models, which<br />

rotates the tool to be balanced. The software<br />

does the rest without any further manual intervention<br />

of the operator.<br />

For the Tool Dynamic Preset Microset combination<br />

unit, the Automatic Drive function<br />

enables fully automatic measuring.<br />

Automation Cube ONE<br />

Smart tool management<br />

Another highlight at EMO was the new integrated<br />

Tool Management System including<br />

Smart Vending Machines. Within the very<br />

short time of only four months the software<br />

WinTool, including the dispensing system<br />

Toolbase, was implemented in the companies<br />

own manufacturing plant with full integration<br />

to the machines. Also additional functions have been enabled in the<br />

software and a new digital process was standardized.<br />

To offer its customers an optimal tool data management and tool dispensing<br />

system, the company cooperates with the TCM Group and its product<br />

lines WinTool and Toolbase. As a software solution for tool and data management,<br />

WinTool enables the management of tools, resources, machine programs,<br />

processes and master data. Toolbase is a smart tool dispensing system<br />

that includes individually configurable tool cabinets and software. It enables<br />

efficient access management via barcode, RFID or manual interaction.<br />

In the future all Microset presetting devices can be equipped with WinTool<br />

as a standard.<br />

Future concept for tool presetting<br />

While all these innovations make the manufacturing process easier for every<br />

machinist and can also be used by small and medium-sized companies to increase<br />

efficiency, the highlight at the booth was mostly aimed at companies<br />

with the highest degree of automation. Talking about the new Automation<br />

Cube One, which can shrink out and in a tool in 60 s, measure it and transfer<br />

the data to the machine and to databases.<br />

Managing director Andreas Haimer explains: “We have learned from our<br />

‘Automation Cube’ pilot project in recent years. In line with customer requirements<br />

our new robotic cell is built as massively as a machine tool. For<br />

this purpose we have brought various partners on board. Siemens supplies<br />

the latest SINUMERIK ONE CNC control. Without the full, fast and highly<br />

competent support from Siemens we would not have been able to realize this<br />

new machine within a record time” emphasizes Andreas Haimer.<br />

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

no.4, November <strong>2023</strong><br />


components<br />

Mould and die suite<br />

Empowering teams to make short work of complex manufacturing<br />

Hexagon’s Manufacturing Intelligence division<br />

released HxGN Mould & Die, a suite of dedicated<br />

CAD/CAM (computer-aided design and manufacturing),<br />

engineering and automation tools empowering<br />

mould and die and tool manufacturers to increase efficiency,<br />

reduce costs and produce high quality tools for<br />

their customers across industries ranging from automotive<br />

to aerospace and beyond.<br />

The suite was developed to empower mould designers and<br />

makers to achieve operational excellence in the design and<br />

manufacturing of plastic injection moulds, progressive dies,<br />

forming dies and similar tools.<br />

Capabilities of the suite include CAD/CAE (computeraided<br />

design and engineering) for plastic injection mould<br />

design, CAD/CAE for progressive die design, CAD for manufacturing<br />

preparation, CAM for CNC (computer numerical<br />

code) machine-tool programming, process simulation and<br />

G-code verification and optimisation, shop-floor production<br />

intelligence and automation and collaboration powered by<br />

Nexus, Hexagon’s digital-reality platform. The suite’s simulation<br />

tools help manufacturers understand the feasibility and<br />

cost of mould-making processes with actionable information.<br />

“We took everything we know about mould-and-die manufacturing,<br />

including our best-in-class Hexagon technologies,<br />

to build a specialized suite that empowers mould and<br />

die shops of any size to get the best results faster,” said Chuck<br />

Mathews, general manager, production software at Hexagon.<br />

“Their competitive edge will be enhanced by Nexus, which<br />

connects desktop software via the cloud to provide further<br />

automation and collaboration opportunities. It also gives<br />

teams an easy way to share 3D models with customers through<br />

secure web-based visualisation, and consolidate access to<br />

libraries for tooling, fixtures, and materials from their desktop<br />

apps.”<br />

“The HxGN Mould and Die suite is an exciting development,<br />

combining our customers’ challenges with our deep<br />

domain knowledge to achieve more. We are refocussing innovation<br />

to bring our ecosystem technologies together and<br />

help production teams to make better informed decisions,<br />

faster,” added Parth Joshi, chief product & technology officer<br />

at Hexagon.<br />

For plastic-injection mould manufacturers the suite provides<br />

tools for design and engineering, flow simulation,<br />

reverse engineering, automated electrode design and CNC<br />

machining. It builds upon Hexagon’s market-leading VISI<br />

and WORKNC software, providing comprehensive multiaxis<br />

CAM programming capabilities, direct modelling of solids<br />

and surfaces and supports the construction, editing and<br />

repair of complex 3D geometry. Reverse engineering tools<br />

allow mould makers to efficiently create solid models from<br />

scanned data – a crucial capability for mould repair and<br />

redesign and for creating solid models for manufacturing<br />

when CAD files are not available.<br />

The suite also provides plastic flow analysis tools that help<br />

shop-floor teams produce cost effective and reliable moulds<br />

that will perform as required. These powerful simulation<br />

capabilities are simple to use, which ensures that non-engineers<br />

or less experienced employees achieve optimal results.<br />

The creation of intricate or difficult-to-machine injection<br />

mould features is further simplified with the automated<br />

design and simulation of EDM (electrical discharge machining)<br />

electrodes and their associated holders.<br />

For progressive die manufacturers, HxGN Mould and<br />

Die offers a connected workflow with tools for design and<br />

engineering, simulation and production. It enables the stepby-step<br />

unfolding of surface and solid models, which gives<br />

designers more control over the development of each forming<br />

stage. Flexible strip layout capabilities and the ability<br />

to simulate the performance of the strip at any stage in the<br />

design process make it easy to quickly analyze the results<br />

of design changes. The software also helps manufacturers<br />

predict springback and offers compensation strategies when<br />

challenges with material performance are identified.<br />

The suite supports shops in fully utilising advanced<br />

machine tools, using trusted Hexagon VISI and WORKNC<br />

software to help programmers optimize machining cycles<br />

and specialized cutting strategies specific to mould production.<br />

Prior to machining, CNC programs can be simulated<br />

and verified using NCSIMUL, the suite’s G-code simulation<br />

software, which incorporates the entire machining environment<br />

to generate an effective digital twin of the machinery,<br />

part and processes.<br />

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

50 no. 4, November <strong>2023</strong>

impressum<br />

ISSN 2628-5444<br />

publisher<br />

Benno Keller<br />

phone + 49 (0)911 - 2018 200<br />

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keller@harnisch.com<br />

editor-in-chief<br />

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eric.schaefer@harnisch.com<br />

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Christiane Ebner<br />

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ebner@harnisch.com<br />

publishing company<br />

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Benno Keller<br />

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Four issues per year<br />

printed by<br />

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Adelbert Haas GmbH ................26<br />

ADICO .............................15<br />

Aerotech GmbH .................... 44<br />

AGELTECH GmbH ..................12<br />

ANCA Pty Ltd.. ................. 24, 40<br />

CemeCon AG .......................31<br />


Deutschland GmbH ......... 14, 22, 25<br />

CHIRON Group SE ................. 42<br />

DN Solutions Europe GmbH ..........37<br />

EMAG GmbH & Co. KG ..............38<br />

EMUGE-Werk<br />

Richard Glimpel GmbH & Co. KG 15, 47<br />

FANUC Deutschland GmbH ..........23<br />

FFG European &<br />

American Holdings GmbH ..........36<br />

Fritz Studer AG .................... 35<br />

Gebrüder Heller<br />

Maschinenfabrik GmbH ............32<br />

GL events Venues. ...................23<br />

Haimer GmbH ......................49<br />

Hartmetall-Werkzeugfabrik<br />

Paul Horn GmbH .............. 18, 30<br />

company finder<br />

Hexagon AB ........................50<br />

KAPP GmbH & Co. KG. . ............ 42<br />

Kern Microtechnik. . .................41<br />

Lach Diamant Jakob Lach<br />

GmbH & Co. KG ................ 6, 19<br />

Leitz GmbH & Co. KG .............. 20<br />

Liebherr Verzahntechnik GmbH . .....34<br />

MAPAL Fabrik für Präzisionswerkzeuge<br />

Dr. Kress KG ..................... 24<br />

Mikron AG, Division Tool ............21<br />

Platinum Tooling Technologies, Inc ....16<br />

Rollomatic SA ......................43<br />

RUD Ketten Rieger & Dietz<br />

GmbH & Co. KG .................. 46<br />

Schunk GmbH & Co. KG ............ 48<br />

Schwäbische<br />

Werkzeugmaschinen GmbH .........28<br />

Tyrolit - Schleifmittelwerke Swarovski<br />

AG & Co. K.G. .....................22<br />


VDMA e. V. .........................11<br />

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copyright © <strong>2023</strong> Dr. Harnisch Publications<br />

advertising index<br />

Adelbert Haas GmbH ................................................ back cover<br />

Aerotech GmbH ........................................................page 13<br />

CERATIZIT Deutschland GmbH ................................ inside front cover<br />

Kapp GmbH & Co. KG ..................................................page 11<br />

Lach Diamant Jakob Lach GmbH & Co. KG .............................front cover<br />

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


SMPLY<br />

PRDC MR<br />


Efficiency can only be achieved by sustainable<br />

optimization, requirements are constantly growing,<br />

and everything is getting fstr and fstr and evn fstr.<br />

Relaax. At Adelbert Haas, we will be looking at<br />

innovative solutions at GrindDialog <strong>2023</strong>.<br />

GrindDialog: 09–10 November <strong>2023</strong> in Trossingen<br />

Save the date, register and benefit immediately:<br />

www.grinddialog.com<br />

↓<br />

Adelbert Haas GmbH<br />


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