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 />
»CONTOUR PROFILED«<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 />
3
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 />
5
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 />
7
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 />
9
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 />
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TECHNOLOGY<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 />
FIND YOUR<br />
SOLUTION
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 />
15
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 />
17
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 />
19
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 />
21
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 />
SMART MANUFACTURING SUMMIT<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 />
23
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 />
25
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 />
27
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 />
29
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 />
31
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 />
33
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 />
35
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 />
37
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 />
39
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 />
41
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 />
43
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 />
45
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 />
47
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 />
49
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 />
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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 />
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MAPAL Fabrik für Präzisionswerkzeuge<br />
Dr. Kress KG ..................... 24<br />
Mikron AG, Division Tool ............21<br />
Platinum Tooling Technologies, Inc ....16<br />
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Schunk GmbH & Co. KG ............ 48<br />
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VDMA e. V. .........................11<br />
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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 />
51
SMPLY<br />
PRDC MR<br />
FFCNTLY<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 />
www.multigrind.com