hpt 2024 #1

Development of customized diamond coatings ■ Process visualization system in the semiconductor industry ■ ■ Extreme surface finish for e-mobility ■ Optimized chamfering of internal gears ■ It was only this little spark

Development of customized diamond coatings ■ Process visualization system in the semiconductor industry ■
■ Extreme surface finish for e-mobility ■ Optimized chamfering of internal gears ■ It was only this little spark


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ISSN 2628-5444<br />

high precision tooling<br />

Machine Tools, PCD, PVD, CVD, CBN, Hard Metal <strong>2024</strong> – 1<br />

■ Development of customized diamond coatings ■ Process visualization system in the semiconductor industry ■<br />

■ Extreme surface finish for e-mobility ■ Optimized chamfering of internal gears ■ It was only this little spark ■


Diamond and CBN wheels<br />

show the claws<br />

U2 no. 1, February <strong>2024</strong><br />

tradition.passion.innovation<br />

www.lach-diamant.de<br />

office@lach-diamant.de<br />

100 years of diamond and CBN tools<br />

®<br />


editorial<br />

Eric Schäfer<br />

editor-in-chief<br />

Nothing is impossible<br />

This was the slogan of a well-known car manufacturer until it gradually became common parlance.<br />

Today, these words are often used to indicate that someone has accomplished something that seems<br />

almost impossible. Nothing is impossible is also the title of the article on page 42, which is about<br />

“Optimized chamfering of internal gears during the machining process”, which opens up<br />

new possibilities in gear manufacturing. In the course of e-mobility, transmissions have undergone<br />

massive changes in terms of design and tolerances. Here, as in medical technology, perfect surfaces<br />

are a challenge.<br />

When the highest surface qualities in the micrometer range are required, grinding is often the method<br />

of choice, as shown in the user reports in this issue of hp tooling. They already give a small foretaste<br />

of the upcoming GrindingHub, the new hub of international grinding technology.<br />

Making the impossible possible has always characterized users of precision tools as well as their<br />

manufacturers. Sometimes all it takes is a small spark to change the world of machining,<br />

as Horst Lach vividly describes in his review of the history of LACH DIAMANT.<br />

If you take a closer look at the “materials & tools” section, you will see how diverse the possibilities<br />

are for finding the right cutting material and the perfect tool geometry for new, demanding machining<br />

tasks that were previously impossible to realize. These range from extremely hard CBN tools for<br />

machining brake discs to customized, extremely hard and wear-resistant diamond coatings for<br />

machining materials such as CFRP, graphite and aluminum alloys to ultra-hard PCD cutting materials<br />

for machining ceramic materials. In short, to make the the impossible possible.<br />

Eric Schäfer<br />

editor-in-chief<br />

no. 1, February <strong>2024</strong><br />


table of contents<br />

cover story<br />

Hybrid manufacturing strategy for reverse shoulder prosthesis component<br />

Developed and tested 6<br />

materials & tools<br />

Extremely hard grade for strong brakes 10<br />

Development of customized diamond coatings 12<br />

Multi-edged PCD tools for machining technical ceramics 14<br />

New end mills for volume machining of aluminum materials 15<br />

processes<br />

High-end surfaces of gears for electromobility 32<br />

written by Janis Thalau and Dr.-Ing. Philip Geilert<br />

Benefit from tried-and-tested grinding technology 34<br />

Complete solution for grinding and eroding 36<br />

Automated cutting edge optimization of stamping and forming tools 37<br />

machining center<br />

Swiss quality as a price leader 38<br />

A benchmark in cutting performance and precision 40<br />

Optimized chamfering of internal gears during the machining process 42<br />

New peripheral and double T-land grinding machine for the European market 43<br />

components<br />

Innovative cutting oils for non-ferrous metal processing 44<br />

Support-free 3D printing opens up new applications and reduces waste 45<br />

New precision clamping fixture simplifies turning and milling processes 46<br />

High-performance coolant filtration for consistent quality in the production of mini tools 48<br />

Ultra black laser marking for medical technology 50<br />

news & facts 17<br />

fairs 5<br />

impressum & company finder 51<br />

4 no. 1, February <strong>2024</strong>

fairs in alphabetical order<br />

AMB Stuttgart, Germany<br />

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

bauma Shanghai, China<br />

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

CMTS Toronto, Canada<br />

(Sept. 29-Octob. 2, 2025)<br />

EPHJ Geneva, Switzerland<br />

(June 11-14, <strong>2024</strong>)<br />

FABTECH Toronto, Canada<br />

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

FEIMEC São Paulo, Brazil<br />

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

current status<br />

<strong>2024</strong><br />

<strong>2024</strong><br />

2025<br />

<strong>2024</strong><br />

<strong>2024</strong><br />

<strong>2024</strong><br />

FILTECH Cologne, Germany<br />

(November 12-14, <strong>2024</strong>)<br />

GrindingHub Stuttgart, Germany<br />

(May 14-17, <strong>2024</strong>)<br />

GrindTec Leipzig, Germany<br />

(March 11-14, 2025)<br />

Hannover fair Hanover, Germany<br />

(April 22-26, <strong>2024</strong>)<br />

hi Tech & Industry Herning,<br />

Denmark<br />

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

IMTS Chicago, USA<br />

(September 9-14, <strong>2024</strong>)<br />

JIMTOF Tokyo, Japan<br />

(November 5-10, <strong>2024</strong>)<br />

METALEX Bangkok, Thailand<br />

(November 20-23, <strong>2024</strong>)<br />

SIAMS Moutier, Switzerland<br />

(April 16-19, <strong>2024</strong>)<br />

SIMTOS Seoul, South Korea<br />

(April 1-5, <strong>2024</strong>)<br />

sps Nuremberg, Germany<br />

(November 12-14, <strong>2024</strong>)<br />

Stone+tec Nuremberg, Germany<br />

(June 19-22, <strong>2024</strong>)<br />

Surface Stuttgart, Germany<br />

Technology (June 4-6, <strong>2024</strong>)<br />

TIMTOS Taipei, Taiwan<br />

(March 3-8, 2025)<br />

TMTS Taichung, Taiwan<br />

(March 27-31, <strong>2024</strong>)<br />

<strong>2024</strong><br />

<strong>2024</strong><br />

2025<br />

<strong>2024</strong><br />

2025<br />

<strong>2024</strong><br />

<strong>2024</strong><br />

<strong>2024</strong><br />

<strong>2024</strong><br />

<strong>2024</strong><br />

<strong>2024</strong><br />

<strong>2024</strong><br />

<strong>2024</strong><br />

2025<br />

<strong>2024</strong><br />

trade fair dates as by end of January <strong>2024</strong>; we are not responsible for reliability of these dates<br />

no. 1, February <strong>2024</strong><br />


cover story<br />

Hybrid manufacturing strategy for<br />

reverse shoulder prosthesis component<br />

Developed and tested by Mikron Tool and DMG MORI<br />

The development specialists at Mikron Tool in Agno, partnering<br />

with DMG MORI and supported by Motorex’s cooling lubricant experts,<br />

have developed a hybrid process to optimize the manufacture<br />

of a “glenoid base plate” (titanium component of a reverse, cementless<br />

shoulder prosthesis).<br />

This was completed in a three-step process: solid base machined on a millturn<br />

machining center, implant post printed on 3D SLM machine, and final<br />

machining completed on a traditional vertical<br />

machining center. The hybrid process has the<br />

potential to become well established in prosthesis<br />

production. Compared to other manufacturing<br />

processes, there are economic and<br />

qualitative advantages.<br />

Mikron Tool, DMG MORI and Motorex<br />

have tested and compared different methods<br />

for manufacturing the complex component<br />

of a titanium shoulder implant (see figures<br />

1 & 2).<br />

• machining with subsequent coating<br />

(hydroxyapatite or titanium coating)<br />

• additive construction with post-machining<br />

on a machining center<br />

• and their combination: hybrid production<br />

1. base plate turned from<br />

solid, milled, drilled<br />

2. surface coating<br />

built up additively<br />

3. post-processing on<br />

machining center<br />

This manufacturing process was presented<br />

at the Mikron Tool Technology Center<br />

in Agno during the 2023 Medical Days (see<br />

figure 8, page 8).<br />

The required production steps were carried<br />

out using the following machines:<br />

figure 1<br />

Production process:<br />

1. machined base plate<br />

2. hollow pin designed with additive manufacturing and<br />

implant surface for osseointegration<br />

3. profiling and thread milling on the machining center type DMP 70<br />

figure 2<br />

Shown here is the<br />

glenoid base plate<br />

produced using the<br />

hybrid process, which<br />

delivers outstanding<br />

quality and return<br />

on investment<br />

1. two-shift pre-machining on the NTX 1000<br />

2. three-shift continuous additive<br />

manufacturing on the<br />


3. single-shift post-processing on the<br />

DMP 70, using milling, drilling, and<br />

thread cutting<br />

1. Complex geometry –<br />

specific surface structure<br />

The geometry of the glenoid base plate is complex.<br />

Ti-6Al-4V ELI titanium is a challenging<br />

material to machine. The implant’s surface<br />

facing the shoulder blade must be porous<br />

to give the bone material the best opportunity<br />

for ingrowth. A hollow pin in the center of<br />

the glenoid base plate is attached to the glenosphere<br />

using a press fit. It serves as a primary<br />

anchorage for the prosthesis in the bone and<br />

requires a specific surface for osseointegration.<br />

Depending on the implant design, the<br />

anchoring can be reinforced with a central<br />

screw, which is guided through the hollow pin<br />

(see figure 3).<br />

6 no. 1, February <strong>2024</strong>

cover story<br />

2. Perfectly aligned interfaces<br />

Combining CNC machining and additive<br />

manufacturing presented several challenges<br />

to the Mikron Tool and DMG MORI specialists.<br />

It was crucial to develop an optimized<br />

workflow for the various production steps and<br />

perfectly coordinate the individual machines’<br />

productivity to ensure the desired final quality<br />

while maintaining high efficiency.<br />

figure 3<br />

Estimates from the USA suggest that the demand for shoulder prosthesis will<br />

increase by 2030 threefold in the group of under 55 years old and eightfold in the<br />

over 55 years old; the aging population aims to maintain a high quality of life<br />

in old age, leading to a worldwide increase in reverse shoulder prostheses<br />

Parts programming with the interfaces<br />

between additive and machining production<br />

plays a key role here. The combination of the<br />

CNC software “Esprit” and the 3D printing<br />

software “Celos” enables seamless integration<br />

of additive and machining production.<br />

2.1 Raw data for 3D printing can be<br />

transferred directly into the<br />

CNC program<br />

Thanks to the software solutions, users can<br />

transfer the raw data for 3D printing directly<br />

into the CNC program. Because of this they<br />

are able to change elements such as surfaces,<br />

design and supporting structures.<br />

figure 4<br />

A custom-fit base plate guarantees optimum positioning accuracy<br />

during laser melting<br />

figure 5<br />

Processing the highly reactive titanium powder requires strict safety measures<br />

and trained staff throughout the production process<br />

figure 6<br />

Laser melting of the hollow pin and the implant surface takes 10 h 16 min.<br />

For areas that need to be reworked, the user<br />

specifies the dimensions so that they can be<br />

optimally processed subsequently. Due to the<br />

flexibility of this stage, the customer gains<br />

multiple benefits that include pro cesses consistency,<br />

decreased cycle time, and increased<br />

reliability, resulting in a repeatable and safe<br />

process.<br />

3. Process progression:<br />

1. machining<br />

2. SLM 3D printing<br />

3. finishing by machining<br />

Based on the results of the previous series<br />

of tests (machining and 3D printing), the<br />

manufacturing specialists decided first to<br />

produce the flat base of the glenoid, including<br />

the screw holes and a central hole with<br />

a thread, from solid material using carbide<br />

tools (“Crazy Tools”) on the mill-turn center<br />

NTX 1000.<br />

The second step involved building the hollow<br />

pin and the required implant surface<br />

directly on the flattened surface of the prefabricated<br />

base using a laser melting process<br />

(see figures 4-6). This approach was chosen to<br />

reduce the amount of used material and the<br />

production time. An additional advantage:<br />

final post-machining on the DMP 70 machining<br />

center was significantly reduced compared<br />

to additive manufacturing alone. From<br />

this stage only the profiles and thread on the<br />

hollow pin were required to be finished (see<br />

figure 7, next page).<br />

no. 1, February <strong>2024</strong><br />


cover story<br />

figure 7<br />

Dr. Alberto Gotti, head of R & D at Mikron Tool,<br />

explains the necessary post-machining steps of a<br />

hybrid-manufactured medical device workpiece<br />

figure 8<br />

Daniel Schmid, senior technical sales support at Motorex and<br />

Marco Cirfeta, head of marketing & sales Europe at Mikron Tool,<br />

during a tour of the production facilities<br />

3.1 Challenging preparation phase<br />

Optimizing the production flow required utilizing the full<br />

capacity of the LASERTEC 30 DUAL SLM, which enabled<br />

the simultaneous production of 56 semi-manufactured forms.<br />

A specially developed component support was used as base<br />

structure, fitted with the appropriate number of customized<br />

pockets to accommodate the glenoid bases.<br />

3.2 Accurate positioning of the base<br />

for 3D printing<br />

The parts had to be carefully screwed to the support plate<br />

to ensure maximum precision during 3D printing. For this<br />

purpose, a thread was added in the middle of the glenoid<br />

base plate, which was manufactured with the NTX 1000. To<br />

ensure even and precise alignment of the base plate on the<br />

support plate, an additional guide groove was added. The<br />

corresponding form was located in the mould cavities. As a<br />

result it was possible to precisely define the angular position<br />

of the parts.<br />

3.3 With a positioning accuracy of 50 µm<br />

Once the base plate had been secured in the pressure chamber<br />

of the LASERTEC 30 DUAL SLM, it was crucial to determine<br />

the exact position of the base on which the material<br />

was to be applied. Precise adjustment of the lasers is essential<br />

for accurate material application, hence a calibration process<br />

is required:<br />

➤ First, the exact zero point of the machining area is<br />

determined. This point serves as a reference for<br />

all subsequent positioning and processing.<br />

➤ Second, automatic referencing is set for moving<br />

the laser head to the predefined positions.<br />

➤ Third, a coordinate measuring device checks the actual<br />

positions of the workpieces, detects deviations and<br />

generates corresponding correction data to ensure<br />

high-accuracy positioning.<br />

Calibration ensures that laser processing meets the highest<br />

quality standards and that the printed parts comply with<br />

the desired specifications. In the example case, the arranged<br />

components achieved a positioning accuracy of 50 µm.<br />

Regarding part handling: for the next step the support<br />

plate with 56 parts was clamped directly into the DMP 70<br />

machining center for final post-machining.<br />

The hybrid manufacturing process developed at Mikron<br />

Tool’s application center has been designed to achieve an output<br />

of 560 parts per week, using the three machines: millturn<br />

center, 3D SLM and milling center (see figure 9).<br />

Let’s review the machining steps and the number of shifts<br />

required:<br />

step 1: pre-machining on the NTX 1000 in two shifts<br />

step 2: 3D printing on the LASERTEC 30 DUAL SLM<br />

in three shifts<br />

step 3: finishing on the machining center DMP 70 in<br />

one shift (see figure 10).<br />

Here the comparison with<br />

other manufacturing processes<br />

Mikron Tool and DMG MORI specialists compared this<br />

manufacturing method with the two traditional manufacturing<br />

processes:<br />

➤ machining with subsequent coating for osseo-integration<br />

➤ and full 3D selective laser melting with<br />

secondary finishing<br />

The hybrid manufacturing process for the shoulder prosthesis<br />

developed by Mikron Tool and DMG MORI is the<br />

most cost-effective and produces the highest quality product.<br />

Anyone interested in the study can contact the Mikron Tool<br />

8 no. 1, February <strong>2024</strong>

cover story<br />

Turning and milling center Additive manufacturing SLM 5-axis machining center<br />

figure 9<br />

Hybrid production chain for producing a glenoid base plate made of titanium Ti6AI4V ELI;<br />

titanium alloys are a considerable challenge both in machining and in additive manufacturing<br />

development and application center directly. There is also a white paper<br />

available that describes the three processes in detail and shows their advantages<br />

and disadvantages.<br />

4. Conclusion: the hybrid process ensures perfect coordination<br />

The series production process developed by the manufacturing experts from<br />

Mikron Tool, DMG MORI and Motorex leads to perfect coordination of the<br />

three involved machines, maximizes their capacity utilization and is characterized<br />

by a high degree of material utilization. Component handling was<br />

reduced to a minimum and the desired quality targets for the medical technology<br />

component were achieved in exemplary fashion.<br />

If we compare hybrid manufacturing within a one-thousand-unit batch,<br />

the cost savings compared to the listed traditional methods are:<br />

4 % compared to machining with coating and<br />

9 % compared to complete additive process with post-machining<br />

There is no doubt that additive manufacturing<br />

will significantly impact many production<br />

processes of the metalworking in the future.<br />

One of the prime benefits of this technology<br />

will be design and manufacture shapes and<br />

geometries that are currently not available for<br />

traditional methods.<br />

The economic success of combining additive<br />

manufacturing and machining depends on<br />

the specific requirements of the component.<br />

In this project, the excellent characteristics<br />

of the additively manufactured implant surface<br />

proved advantageous. Not only is it more<br />

durable, but its structure is also considerably<br />

more stable than applied coatings.<br />

Compared to machining, the dimensional<br />

tolerances of laser melting technology are<br />

smaller, which is why the need for post-processing<br />

steps cannot be completely ruled out.<br />

In fact, the precision of CNC machining is<br />

much more accurate, reaching values of up<br />

to 0.005 mm. In addition, the machining processes<br />

offer greater repeatability and excellent<br />

surface qualities.<br />

Nevertheless, the new hybrid process will<br />

set new standards, both in terms of technology<br />

and cost efficiency.<br />

figure 10<br />

The hybrid-manufactured medical device components require only a minimum<br />

number of post-machining steps; machining the parts in a single clamping process<br />

is friction-locked and highly efficient<br />

further information:<br />

www.mikrontool.com<br />

www.dmgmori.com<br />

www.motorex.com<br />

no. 1, February <strong>2024</strong><br />


materials & tools<br />

Extremely hard grade for strong brakes<br />

Horn is launching a new product range<br />

for the economical machining of brake disks<br />

Horn is launching a new product range for the economical<br />

machining of brake disks. This includes solid<br />

CBN ISO inserts and solid CBN-tipped full radius and<br />

shaped inserts. In addition to the inserts, stable tool<br />

carriers round off the product range.<br />

“With the performance of the grade, we can almost bring a<br />

lathe to its knees,” says Horn product manager for ultra-hard<br />

cutting materials, Aribert Schroth. The talk is about cubic boron<br />

nitride (CBN), or solid CBN to be precise. The grade has<br />

no metallic bonding phase and therefore has the highest hot<br />

hardness of all cutting materials. In addition, the abrasion resistance<br />

increases compared to CBN substrates. Solid CBN is<br />

mainly used for cast iron machining.<br />

In addition to the inserts,<br />

stable tool carriers round<br />

off the product range for<br />

the economical<br />

machining of<br />

brake disks<br />

Cutting speeds of well over 1,000 m/min (3,280.84 ft/min),<br />

depths of cut of several millimeters and feed rates of up to<br />

0.7 mm/rev (0.028"/rev) are typical when machining brake<br />

discs made from cast materials. The tool system used must<br />

be able to keep up and, above all, last a long time. The tool<br />

life requirements are high due to the price per cutting edge of<br />

solid CBN. Depending on the operation and metal removal<br />

rate, well over 1,000 brake discs can be machined per insert<br />

corner. Horn offers two different tool solutions for machining<br />

the heat compensation groove of a brake disc. The tipped<br />

S117 profile grooving insert is ideal for large batch production<br />

in terms of speed and long tool life. During the process,<br />

the groove is produced in just under two seconds in a single<br />

operation. For greater flexibility, the company provides<br />

S229 tipped full radius inserts. They offer the option of copy<br />

turning the heat compensation groove in about four seconds.<br />

Regrinding and re-tipping are possible with both types.<br />

For further machining applications on a brake disc, Horn<br />

offers a solid full CBN ISO S insert with eight cutting edges.<br />

In conjunction with the tool holder the tool system is suitable<br />

for roughing and finishing. The neutral design of the inserts<br />

fully utilizes the number of cutting edges. This means<br />

that eight cutting edges per ISO insert are available for most<br />

turning operations. The tool holder combines important<br />

criteria: the frictional connection between the carbide thrust<br />

pad and the insert occurs via a defined annular surface. This<br />

prevents compressive stresses on the CBN insert. Engagement<br />

of the thrust pad in the bore of the insert pulls it into the<br />

insert seat of the tool holder with a secondary force. This<br />

prevents clamping errors and increases precision.<br />

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

10 no. 1, February <strong>2024</strong>

materials & tools<br />

New product lines provide versatility,<br />

value in wide variety of machining applications<br />

fiberboard (MDF), melamine, laminates, particleboard, stone,<br />

concrete and other difficult-to-machine applications.<br />

“The extension of Hyperion’s PCD portfolio offers more<br />

flexibility to our customers in choosing the right material for<br />

each job they pursue, all from one trusted and credible supplier,”<br />

said Hilary Interrante, Hyperion’s segment manager of<br />

Diamond Solids. “Our aim is to support our partners as the<br />

PCD tooling industry evolves.”<br />

Hyperion Materials & Technologies, a leading<br />

manufacturer of hard and super-hard materials for<br />

a variety of demanding industrial applications, is<br />

excited to announce the launch of two new polycrystalline<br />

diamond (PCD) lines, the P-Series and<br />

U-Series, that expand the company’s offering to the<br />

toolmaking industry.<br />

“Both product lines maximize value for performance and<br />

feature a higher level of quality consistency than is offered<br />

elsewhere due to Hyperion’s advanced quality control techniques<br />

that ensure the highest level of integrity for every<br />

blank shipped,” said Karl Tuffy, general manager of<br />

Hyperion’s Diamond business unit. “Hyperion is excited to<br />

offer these new product lines alongside its industry-leading<br />

premium COMPAX® PCD line.”<br />

P-Series PCD is specially designed for tools used in machining<br />

nonferrous and nonmetallic workpieces for automotive,<br />

aerospace, electronics and other precision applications<br />

that demand consistent performance and long-term<br />

cost savings. P-Series PCD delivers outstanding results<br />

across a diverse range of workpieces, including aluminum,<br />

metal matrix composites, copper, carbon-fiber-reinforced<br />

polymers (CFRP) and other precision applications.<br />

U-Series PCD is explicitly designed for tools used in<br />

machining nonferrous and nonmetallic workpieces in<br />

woodworking, heavy machinery and other utility applications.<br />

This product line enables toolmakers to optimize<br />

costs without sacrificing reliability in machining applications<br />

where competitiveness and consistency are critical.<br />

Suggested applications include, wood, medium-density<br />

The P-Series and U-Series PCD lines are offered as discs with<br />

a 62 mm usable area and as cut tips in either standard shapes or<br />

to customer drawings. Learn more about P-Series and U-Series<br />

PCD by visiting Hyperion’s PCD product pages.<br />

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

TRUST IN<br />


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materials & tools<br />

Development of<br />

customized diamond coatings<br />

With its in-depth knowledge in the field of coating technology, MAPAL also develops extremely hard and<br />

wear-resistant diamond coatings for machining materials such as CFRP, ceramics, graphite and aluminum<br />

alloys. MAPAL’s machining solutions thus achieve longer tool lives and more process reliability especially for<br />

applications in the automotive and aerospace industry, in the die & mold sector and in medical technology.<br />

Inside view of a reactor during the HF CVD coating process<br />

The tool manufacturer has coating technologies<br />

at its site in Aalen and in its centers of<br />

competence to coat indexable inserts and<br />

solid carbide tools using PVD or CVD processes.<br />

The choice of process depends on the<br />

relevant application parameters. For dry machining<br />

and high cutting speeds usually CVD<br />

is chosen; in the case of unstable machining<br />

situations or difficult machining conditions,<br />

the tougher PVD coatings are applied.<br />

If adhesive wear processes occur frequently<br />

when machining, the use of diamond-like<br />

carbon coatings (DLC) is advisable. DLC<br />

coatings are also deposited using PVD or a<br />

plasma- enhanced CVD process. These coatings<br />

are formed by a mixture of sp 2 hybridized<br />

carbon atom bonds (graphite) and those with<br />

The homogeneous CVD diamond coating from MAPAL ensures long tool lives and<br />

a high level or process reliability, for example with the OptiMill-Composite-Speed-<br />

Plus solid carbide milling cutter for CFRP workpiece materials<br />

SEM image of the break edge of a<br />

diamond-coated solid carbide tool<br />

(3,000x enlarged)<br />

12 no. 1, February <strong>2024</strong>

materials & tools<br />

sp 3 hy bridization (diamond). The mixing ratio determines<br />

the physical and mechanical properties of the coatings. The<br />

more sp 3 atomic bonds, the harder the coating.<br />

New coating processes thanks to<br />

CVD diamond reactors<br />

Pure diamond coatings are required for milling or drilling<br />

highly abrasive materials. The process used in the MAPAL<br />

Group for the synthesis of diamond coatings is a modification<br />

of purely thermal CVD and is called hot filament CVD,<br />

or HF CVD for short. Conventional CVD coatings are not<br />

suitable for coating shank tools because the tool lengths and<br />

the high coating temperatures usually result in length distortion.<br />

In HF CVD, wires made of refractory metals heat up a<br />

mixture of hydrogen and methane to temperatures of up to<br />

2,500 ° C. In the process very reactive methyl radicals are<br />

formed, which are gradually deposited on the seeded carbide<br />

surface as a diamond layer. The company has own CVD diamond<br />

reactors at its disposal.<br />

“In recent years we have worked extensively on improving<br />

the diamond coating process and have created new<br />

possibilities for MAPAL in tool production”, explains<br />

Dr. Martin Kommer, team leader R&D Cutting Material /<br />

Coating at the company. The tool manufacturer has the complete<br />

tool design now under its own control, from the appropriate<br />

geometry to the selection of a suitable carbide to the<br />

coating. This means that tools can be designed even more<br />

precisely to meet customers’ requirements. The development<br />

department in Aalen has its own center for machining, which<br />

tests new tools for tool life and wear behavior, among other<br />

things.<br />

Since the coating process functions via a chemical reaction<br />

combined with mechanical clamping, defined etching of the<br />

carbide surface and seeding are important during pre-treatment.<br />

As not every carbide is suitable for this, MAPAL evaluates<br />

appropriate substrates. Whether fine-grained microcrystalline<br />

or nanocrystalline layers are produced during coating<br />

is determined by the temperature, pressure and flow of the<br />

respective reactive gases during the process.<br />

Theoretically, layers up to a thickness of 50 µm can be produced<br />

by HF-CVD. For coating its tools, the company currently<br />

focuses on the range between 3 µm and 15 µm, depending<br />

on the respective application.<br />

The optimized HF CVD process produces layers with almost<br />

uniform thickness, which MAPAL used when developing<br />

its OptiMill-Composite-Speed-Plus. In the respective<br />

machining application, the entire cutting edge length can<br />

thus be reliably used regardless of the cutting depth.<br />

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

Milling competence<br />

right down the line<br />

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

removal at extremely smooth running<br />

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

reduction and optimal distribution of cutting<br />

force<br />

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

most difficult conditions<br />

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

system for mould and die<br />

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

for every application<br />


materials & tools<br />

Multi-edged PCD tools for<br />

machining technical ceramics<br />

Workshop sample component and cutters and drills<br />

used from the MARLIN tool series<br />

In recent decades there has been fundamental<br />

change in the world of ceramic materials. The variety<br />

of different compositions influence the properties of<br />

ceramics depending on their intended use.<br />

How ever, two characteristics make the processing<br />

of these materials especially difficult: their high<br />

degree of hardness and their brittleness. In the past<br />

this necessitated the use of complex production<br />

methods. Grinding and polishing processes were often<br />

employed.<br />

ZECHA has recently developed an innovative solution for exactly<br />

this type of material. State-of-the-art laser technology<br />

is used to create previously impossible tool geometries from<br />

ultra-hard cutting materials such as PCD and CVD.<br />

Thanks to the use of lasers, these geometries can be designed<br />

to be even more delicate, precise and intricate.<br />

In addition many more cutting edges can be applied to the<br />

tool, especially with small tool diameters. A 0.6 mm torus<br />

cutter with 42 cutting edges is just one example of the many<br />

possibilities offered in our 3D-Marlin series brochure.<br />

A higher number of cutting edges means a better distribution<br />

of cutting force, less heat generation and an increased<br />

tool life. It is helpful that the MARLIN-3D series internal and<br />

shank cooling, which also minimizes friction and tool wear.<br />

All of this contributes to our goal of achieving great surface<br />

quality and process reliability.<br />

Successful workshop raises the profile of ceramic<br />

milling: A new approach to micro-machining<br />

In May 2023, ZECHA and its main partners organized a<br />

seminar at the Teisnach University of Applied Sciences to<br />

highlight both the challenges of ceramic machining and the<br />

performance of this new generation of tools.<br />

In addition to presentations on the material properties of<br />

technical ceramics by Teisnach University, tool selection by<br />

ZECHA, programming by OPEN MIND and machine technology<br />

by Röders and WESCHU, there was also a live machining<br />

demonstration. A total of forty participants from 21<br />

companies were particularly impressed by the measurement<br />

results from Teisnach University.<br />

➢ surface roughness Ra in the nanometer range<br />

➢ minimal shape deviations from CAD<br />

➢ flatness in the µm range<br />

➢ chipping in the µm range<br />

The success story continues: workshops upcoming<br />

The success of the Teisnach seminar means that it will be organized<br />

again! In November 2023, another purely ceramic<br />

workshop was held in the Allgäu Regio, once again focusing<br />

on micro-machining. Further workshops on this topic are<br />

also planned for <strong>2024</strong> in German-speaking areas so the industry<br />

can be kept up-to-date with the latest ceramic milling<br />

developments. Moreover, ZECHA will also be present at the<br />

ceramitec trade fair in April <strong>2024</strong> with its own stand.<br />

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

14 no. 1, February <strong>2024</strong>

materials & tools<br />

New end mills for<br />

volume machining of aluminum materials<br />

The Alu-Cut “Aerospace” WF end mills from FRANKEN are specialist tools for<br />

volume machining of aluminum and are designed for use in the aerospace industry<br />

The Alu-Cut “Aerospace” WF series from<br />

FRANKEN’s represents an end mill family made of<br />

carbide and HSSE-PM for volume machining in aluminum<br />

materials. The Alu-Cut “Base” product line is<br />

supplemented by new diameters and lengths.<br />

The new high-performance tools of the Alu-Cut “Aerospace”<br />

WF range were specifically developed for the process-reliable<br />

volume machining of aluminum and copper alloys in<br />

the aerospace industry. The uncoated version was designed<br />

to machine wrought aluminum alloys and cast aluminum<br />

alloys with a silicon content of up to 7 %. There are also GLTcoated<br />

versions available for cast aluminum alloys with a silicon<br />

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

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

low-vibration roughing and finishing of aluminum. The WF<br />

cutting edge geometry for aluminum machining is available<br />

with and without corner radius and in two length versions.<br />

The end mills have an internal coolant-lubricant supply with<br />

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

New lengths and diameters for Alu-Cut Base<br />

The Alu-Cut “Base” product range includes high-performance<br />

end mills with different geometries for universal<br />

use in aluminum and copper alloys. Volume machining<br />

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

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

with finishing teeth can achieve dimensionally accurate and<br />

high quality surfaces without losing flexibility. In addition to<br />

the end mills fitted with a chamfer, the product line is supple-<br />

The Alu-Cut “Base” product line is available as<br />

end mills with chamfer and in versions with corner radius<br />

mented by different variants with corner radius in order to<br />

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

on the component.<br />

The existing geometries are supplemented by the 0 14 and<br />

18 mm. In addition there are two new lengths: 3.5 x D and<br />

6 x D.<br />

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

no. 1, February <strong>2024</strong><br />


materials & tools<br />

The new kid in town<br />

It’s official! SPR Abrasives GmbH, located south of<br />

Berlin, has been founded. SPR Abrasives is the result<br />

of a collaboration between three well-known companies<br />

in the superabrasives industry.<br />

Despite their great differences these companies can create<br />

enormous synergies by working together. Their different<br />

activities, interests, geographical locations and backgrounds<br />

can strengthen each other. It certainly helps that the owners<br />

and employees have known each other for years or even<br />

decades and that there is already a strong mutual trust.<br />

The basic outline of the company was established back in<br />

January 2023 and has been gradually expanded in recent<br />

months. Decisions were made about the product range, and<br />

production areas and machines were ordered and set up. Production<br />

(plating) is ready to start in the first quarter of <strong>2024</strong>.<br />

What can customers expect from SPR?<br />

The first products available will include CBN powders, resin<br />

and metal bond powders, in both mesh and saw grit sizes.<br />

The required micron powders will also be offered and SPR<br />

will distribute natural diamond powders.<br />

All abrasives first undergo a fusion process in the company’s<br />

own facilities south of Berlin. They are then sieved<br />

and tested for strength. Then they can be coated with the desired<br />

metal to meet individual customer requirements. Despite<br />

this additional quality boost, the entire product range is<br />

offered at competitive prices. SPR works closely with its customers<br />

to develop customized coatings and continually pushing<br />

the boundaries of innovation to find the ideal solution.<br />

SPR also offers a number of exclusive services. Customers<br />

can have products, that they have purchased elsewhere, or old<br />

stock, cleaned or screened and subjected to the same rigorous<br />

testing in SPR’s laboratories. An important service is reclaim,<br />

where customers can recover their powders used in electroplating<br />

from waste liquids. This allows to reuse materials,<br />

which is considerably cheaper than buying new powders.<br />

Furthermore, SPR’s product range includes a wide variety<br />

of polycrystalline diamond and CBN (PCD and PCBN) as<br />

well as CVD diamonds, single crystal synthetic diamonds,<br />

and HPHT diamonds. The company is proud to offer customi<br />

za tions to cover special laser and wire EDM cutting<br />

needs and to supply to customer’s specifications.<br />

The power of partnership<br />

SPR is the result of a collaboration between three companies<br />

in the superabrasives industry. They are three complete<br />

different companies, each with its own identity, its own<br />

approach and its own product focus, spread across three countries<br />

and two continents. But it is precisely these differences<br />

that make their collaboration so strong. VDiamant’s laboratory<br />

and production facilities for testing and manufacturing<br />

abrasive powders are unparalleled in Europe. Gemmata<br />

has been a global player in the field of industrial natural diamonds<br />

for decades, while American Superabrasives is one of<br />

the largest distributors of superabrasives, powders and solids<br />

in the United States.<br />

All three partners have a large customer base worldwide<br />

with rela tively little overlap. There is an excellent relationship<br />

between the three of them so everyone knows “who does<br />

what” and the different team members complement each<br />

other perfectly and do what they love to do! As a result of all<br />

these factors SPR will undoubtedly become a strong player in<br />

the superabrasives market. The combined expertise in sourcing,<br />

production, marketing, customer relations and laboratory<br />

services will enable SPR to make a significant and lasting impact<br />

in the world of superabrasives.<br />

Each partner will also act as a representative SPR office for<br />

their own local markets, ensuring that all customers have a<br />

known point of contact in their own place of business.<br />

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

16 no. 1, February <strong>2024</strong>

news & facts<br />

Experience the future of<br />

connectivity live in Shanghai<br />

Interested parties in China, too, can now explore<br />

umati more fully, and experience the benefits of open,<br />

standardized OPC UA-based inter-faces live and in<br />

person. The joint connectivity initiative of the VDW<br />

(German Machine Tool Builders’ Association) and<br />

VDMA (German Mechanical Engineering Industry<br />

Association) opened the “Smart IoT in Production”<br />

showroom in Pudong near Shanghai, China, in<br />

November 2023.<br />

The event was attended by deputy consul general Lukas Meyer<br />

of the Consulate General of the Federal Republic of Germany<br />

in Shanghai, representative Yugang Zhao of the Free Trade<br />

Zone Administration and numerous invited guests. Dr.<br />

Alexander Broos, head of Research and Technology at the<br />

VDW (German Machine Builders’ Association), Frankfurt<br />

am Main, and umati project manager, is delighted with the<br />

new possibilities opened up by the showroom: “The future of<br />

connectivity is digital – but sometimes a physical platform is<br />

needed: a place where people can share ideas and products<br />

can be presented. The showroom highlights in tangible form<br />

the benefits of umati – in China, one of the most important<br />

and largest markets for the industry.”<br />

The showroom is a joint facility of the VDW and the operator<br />

of the IMT (International Machine Tool Center) in the<br />

Pilot Free Trade Zone, where the VDW already has its local<br />

office.<br />

In future companies can present their smart production<br />

technology to the public and meet potential customers and<br />

partners at these premises covering a total of roughly 500 m 2 .<br />

Permanent exhibition stands can be hired for this purpose.<br />

The first exhibitors include the Chinese subsidiaries of<br />

Liebherr-Verzahntechnik from Kempten and the United<br />

Grinding Group from Bern, Switzerland. David Feng, head of<br />

the Gear Cutting Machines & Automation Division at Liebherr-Verzahntechnik<br />

in China, one of the first companies to<br />

About the VDW<br />

The German Machine Tool Builders’ Association (VDW),<br />

headquartered in Frankfurt am Main, has been the mouthpiece<br />

of the German machine tool industry for more than 130 years.<br />

It represents its members’ interests vis à vis the political and<br />

scientific communities, business partners and the general<br />

public, both nationally and internationally. In addition to<br />

offering many valuable services to its members, the VDW has<br />

been organizing trade fairs for the industry for over 100 years.<br />

It stages various events which carry the “VDW trade fair”<br />

seal of approval. These include: EMO Hannover (next fair<br />

September 22-27, 2025) which it runs on behalf of the<br />

European machine tool association Cecimo, and GrindingHub<br />

(next fair May 14-17, <strong>2024</strong>) together with Messe Stuttgart.<br />

Until 2022 it organized also the METAV in Düsseldorf,<br />

International Trade Fair for Metalworking Technologies.<br />

Official opening of the “Smart IoT in Production” showroom<br />

in Shanghai in November 2023<br />

(source VDW)<br />

hire an exhibition stand in the showroom: “The ‘Smart IoT in<br />

Production’ showroom in Shanghai offers Chinese industry<br />

an application scene with real time capability. This will help<br />

local industrial users to experience first-hand how umati can<br />

help them meet the future challenges of smart manufacturing<br />

trends.”<br />

umati has a permanent exhibition stand which it uses<br />

to present the possibilities of open data networking based<br />

on OPC UA. It also serves as a basis for cooperation with<br />

Chinese companies and the local connectivity initiative, NC<br />

Link. An intelligent caliper from Mahr, Göttingen, and a<br />

marking laser from Trumpf, Ditzingen, are being integrated<br />

into the umati dashboard in order to provide a live demonstration<br />

of networking from China. Georg Fischer Machining<br />

Solutions, Schaffhausen, Switzerland, also connected a machine<br />

in a live demonstration. Deputy consul general Lukas<br />

Meyer emphasizes the importance of umati: “There is currently<br />

a lot of buzz surrounding Industry 4.0, making it now<br />

all the more important to ensure full transparency. With its<br />

powerful network of partners and its international approach,<br />

umati is laying important groundwork here. The ‘Smart IoT<br />

in Production’ showroom represents a further important way<br />

for the network to raise its profile.”<br />

Broos also emphasizes the global aspect of the showroom<br />

in China: “The dashboard is the same as the one used in the<br />

rest of the world. This offers further proof that there is no reason<br />

for the consistent implementation and use of open data<br />

interfaces to stop at national borders. Connectivity is a global<br />

issue in mechanical engineering.” The showroom is open to<br />

all companies based in the IMT as well as all umati partners<br />

in China. It can also be used as an event location. Anyone<br />

interested can find out more at the following address:<br />

https://umati.org/dcs/<br />

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

no. 1, February <strong>2024</strong><br />


news & facts<br />

Cutting tools inspire creativity and brilliance<br />

The ANCA Tool of the Year Awards marked its sixth<br />

year with a record attendance of hundreds of industry<br />

professionals at the awards ceremony and gala dinner<br />

held at EMO Hannover.<br />

EMUGE-FRANKEN, a renowned German cutting tool<br />

manu facturer, took first prize for their multi-functional carbide<br />

tool infused with ceramic material, promising extended<br />

tool life and unparalleled performance.<br />

JG Group from Poland secured first place in the Virtual<br />

Tool Category for the second consecutive year with an impressive<br />

simulation of a Dachshund – or more commonly<br />

known as the sausage dog, that used 24 profiles just to create<br />

the head of its character.<br />

EMUGE-FRANKEN’s multi-functional carbide tool<br />

infused with ceramic material<br />

Machinist’ category at ANCA. Recognizing women who are<br />

choosing to enter our industry is paramount, and we extend<br />

our heartfelt congratulations to Lena, the deserving winner<br />

of this historic category.”<br />

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

Finalists<br />

This year’s awards held a special significance as ANCA announced<br />

Lena Risse from Risse Tool Technology GmbH as the<br />

winner of the inaugural Female Machinist of the Year award.<br />

This initiative aims to promote diversity in the cutting tool<br />

industry and provide positive role models for women and<br />

girls considering careers in this sector.<br />

Pat Boland, ANCA Co founder said: “This year has been<br />

marked by exceptional enthusiasm, boasting an impressive<br />

array of entries and showing a remarkable complexity in the<br />

design of both real and simulated tools. The competition was<br />

fierce, but EMUGE-FRANKEN, a globally renowned cutting<br />

tool manufacturer hailing from Germany, has truly set itself<br />

apart. Their combination of ceramic materials and tungsten<br />

carbide posed a significant manufacturing challenge and<br />

effectively extended the performance and lifespan of the cutting<br />

tools.”<br />

“JG Group’s whimsical ‘sausage dog’ entry added a delightful<br />

touch to the competition, underscoring the remarkable<br />

flexibility of our software and the impressive results that can<br />

be achieved when blending creativity and expertise. Moreover,<br />

we were honored to introduce the inaugural ‘Female<br />

Made on ANCA<br />

winner: EMUGE-FRANKEN<br />

Their winning entry was a complex, multi-functional cutting<br />

tool with edges consisting of carbide and ceramic material.<br />

Using iGrind to its fullest, this tool makes the most of the<br />

profile software’s flexibility, employing layers and segments<br />

to assign operations efficiently. Demonstrating exceptional<br />

precision in profile measurements and 3D edge radius<br />

measurements, the tool closely aligns with its intended<br />

specifications and stands out for its accuracy.<br />

second place: ARCH Cutting Tools<br />

ARCH Cutting Tools continues to create another outstanding<br />

multi-functional cutting tool with the required accuracy. Once<br />

again, it proves to be a functional tool to replace multiple<br />

processes, thanks to its use of profile software, segments and<br />

other iGrind operations during its creation. The cutting edges<br />

exhibit consistent 3D edge radius and good levels of profile<br />

accuracy.<br />

third place: TDM Cutting Tools<br />

This tool has been designed to replace multiple processes,<br />

and it’s the result of combining profile software, segments,<br />

and various iGrind operations. With its profile and edge<br />

radius meeting satisfactory standards, it’s worth noting<br />

that this is a complex tool overall.<br />

18 no. 1, February <strong>2024</strong>

130 years ago, Hermann<br />

Heller opened a trading<br />

and manufacturing<br />

company for patented<br />

products and<br />

watchmaking tools in<br />

Nürtingen.<br />

With the business selling<br />

tools of all kinds, the engineer<br />

laid the foundations<br />

for the long- term<br />

success of the company,<br />

which entered the mechanical<br />

engineering sector<br />

in 1898 with the pro - HELLER production in 1967<br />

duction of cold circular<br />

saws for metal cut ting<br />

and the ma nufacture of<br />

blade skiving and thread<br />

cutting machines. In 1900, Hermann Heller’s brother Ernst, a<br />

trained tradesman, joined the company, marking the birth of<br />

“Gebr. Heller Werkzeug- und Maschinenfabrik” in Nürtingen.<br />

Hubert and Berndt Heller as<br />

managing directors of the machine factory<br />

In the 1960’s, Hubert and Berndt Heller took over the manage<br />

ment of the machine factory and developed the company<br />

into an internationally successful group of companies with<br />

numerous locations in all major markets – including the production<br />

plants in England (Redditch) and Brazil (Sorocaba),<br />

which will be celebrating their 50 th anniversaries this year.<br />

However, not all was plain sailing for HELLER. “The era of<br />

the economic miracle was over and we now had to assert ourselves<br />

in the field of tension between economic fluctuations<br />

and tougher competition,” recalls Berndt Heller, HELLER’s<br />

HELLER is 130 years old<br />

news & facts<br />

long-standing CEO and<br />

former chairman of the<br />

super visory board, at the<br />

beginning of his management<br />

career in the family<br />

business. The brothers’<br />

instinct for innovation<br />

was the key to success in<br />

difficult times and times<br />

of crisis. With the development<br />

of modular machining<br />

centers and Flexible<br />

System Transferlines<br />

(FST) in the 1990’s, they<br />

led the company out of<br />

HELLER production today one of the most serious<br />

crises in its history, putting<br />

it back on track. “We<br />

achieved this with the<br />

help of our employees,<br />

who have always given their best – even in what has sometimes<br />

been difficult circumstances. They deserve my utmost<br />

respect and have played an important role in the company’s<br />

130-year history,” Heller continues.<br />

Looking to the future with a spirit of<br />

tradition and innovation<br />

To this day the Heller family has maintained the spirit of a<br />

family-run business with a strong sense of tradition. Since<br />

2016 all shares in the group have been wholly owned by the<br />

family. Berndt Heller’s children, Nicole Pfleiderer and Marc<br />

Heller are shareholders in the company. The group is currently<br />

managed by Dr. Thorsten Schmidt (CEO), Andreas Müßigmann<br />

(CFO), Dieter Drechsler (COO) and Peter Weber (CSO).<br />

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

Platinum Tooling now offering<br />

Hommel+Keller QUICK catalog<br />

Platinum Tooling, the importer and master distributor<br />

of live tools, angle heads, marking tools, Swiss<br />

tools and multi-spindle tools manufactured by various<br />

global suppliers, is the North American importer<br />

of the QUICK knurling and marking tools from<br />

Hommel+Keller. They have just released the full tooling<br />

catalog.<br />

Hommel+Keller manufactures the QUICK line with a combination<br />

of function and innovation. Quality, precision and stability<br />

are the key principals used to make QUICK® tools successful.<br />

Furthermore the company prides itself on a rich history<br />

of providing customized solutions for its customers.<br />

Benefits of cut knurling include maximum precision and<br />

surface quality, knurling of thin-walled components without<br />

deformation and time savings due to faster cutting speed<br />

and feed rate. Additional advantages are machining of virtually<br />

all materials (including gray cast iron and plastic), zero<br />

or only minimal alternation of the workpiece diameter and<br />

minimal surface compaction.<br />

In form knurling, machining of the workpiece by cold<br />

forming compresses the surface of the workpiece. Knurling<br />

is possible up to a workpiece shoulder, at any position of the<br />

workpiece of the inner and end faces as well as conical. All<br />

knurling profiles according to DIN 82 can be produced.<br />

QUICK also has knurling tools with interchangeable jaws<br />

and knurling wheels available from stock. Wheels with special<br />

dimensions and pitches can be customized.<br />

QUICK marking tools can mark workpieces in seconds<br />

and on a wide variety of geometries independent of workpiece<br />

diameter. They are ideal for machines with small installation<br />

space and can mark up to a shoulder.<br />

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

no. 1, February <strong>2024</strong><br />


news & facts<br />

Stronger pre-sales support for the European market<br />

Following the successful debut after its name change<br />

to DN Solutions at EMO Hannover last September,<br />

DN Solutions is now taking its customer support in<br />

Europe to a new level: with the opening of its first<br />

Technical Center in Germany.<br />

With this expansion, the machine tool manufacturer is<br />

strengthening its pre-sales support in the European market.<br />

The Center in Dormagen, North Rhine-Westphalia was officially<br />

opened November 22.<br />

With the grand opening of its Technical Center in North<br />

Rhine-Westphalia, DN Solutions underlines its growth strategy<br />

in Europe and its market position as one of the world’s<br />

largest manufacturers of CNC machine tools. More than 200<br />

partner customers and guests attended the two-day opening<br />

ceremony at the end of November. The event kicked off<br />

with speeches from Kim Wonjong, CEO of DN Solutions, and<br />

Stefanie Frank, CEO of Siemens MTS.<br />

Various automation solutions and<br />

machining demonstrations<br />

The Center, spanning an impressive 1,000 m 2 , features a<br />

range of cutting-edge facilities. At the opening ceremony the<br />

company gave visitors live demonstrations of twelve ultramodern<br />

CNC machines on the showroom floor. The focus<br />

was on advanced automation solutions in collaboration with<br />

various specialized automation suppliers. Visitors were able<br />

to see the seamless integration of various advanced machining<br />

solutions for themselves:<br />

➤ the compact turning center (PUMA DNT2100),<br />

which is equipped with a collaborative robot,<br />

➤ the two-spindle horizontal turning center<br />

(PUMA TW2600M), which is integrated with a<br />

gantry loader, and<br />

➤ the compact vertical 5-axis machining center<br />

(DVF 4000) with automatic workpiece changer (AWC)<br />

DN Solutions also presented industry-orientated machining<br />

solutions – e.g. for aerospace and electric motors – in conjunc-<br />

With the new Technical Center in Dormagen DN Solutions<br />

is strengthening its pre-sales support in the European market<br />

At the opening ceremony DN Solutions gave visitors<br />

live demonstrations of twelve ultra-modern CNC machines<br />

on the showroom floor<br />

tion with clamping solutions and advanced machining technologies<br />

such as dynamic turning.<br />

Clear focus on customer service<br />

DN Solutions has set itself the goal of improving its pre-sales<br />

service. The new Technical Center serves as a consulting<br />

hub for interested parties, who can find out about suitable<br />

machine tools and their peripherals. Companies can test the<br />

machining process on request, including a time study and<br />

machining. For this purpose, at least ten different machine<br />

types – with a special focus on high-end machines – will be<br />

on permanent display even after the opening. The Center also<br />

has a design workshop, a spindle reconditioning center, and a<br />

spare parts warehouse.<br />

The Technical Center has far-reaching, long-term goals. It<br />

will expand its role to serve as a technical hub for turnkey<br />

projects, develop its automation retrofit department and<br />

become a reliable one-stop solution provider for everything<br />

related to customers’ manufacturing. Technical seminars<br />

for customers and partners will also be organized regularly<br />

throughout the year.<br />

Closer to the European market<br />

“Both the Technical Center and the planned research and<br />

development center are the first of their kind in Europe,” said<br />

Kim Wonjong, CEO of DN Solutions. “In a market as dynamic<br />

as Europe, where numerous cutting-edge technologies like<br />

Industry 4.0 and additive machining are evolving, our presence<br />

in the region is pivotal. These centers will not only<br />

enhance our understanding of the European market but also<br />

enable us to cater to its unique needs and evolving trends.<br />

We are confident that this move will not only strengthen<br />

our foothold but also foster valuable connections with our<br />

European customers.”<br />

further information: www.dn-solutions.com<br />

20 no. 1, February <strong>2024</strong>

news & facts<br />

Expansion of sales and support activities in Austria<br />

Okuma is further expanding its operations across Europe. The<br />

well-known CNC machine tools manufacturer acquired the<br />

Austrian company, precisa CNC-Werkzeugmaschinen GmbH, with<br />

effect January 1, <strong>2024</strong>.<br />

The Vienna-based company will now operate under the name Okuma<br />

Austria GmbH and focus on improving customer service and sales.<br />

“As the exclusive sales partner for Okuma in Austria for over 35 years,<br />

precisa CNC-Werkzeugmaschinen has been a significant key to our success<br />

there. Now that it is our wholly owned subsidiary, we can continue and expand<br />

our business. We firmly believe that combining resources and expertise<br />

will lay the groundwork for a prosperous future”, says Norbert Teeuwen,<br />

Okuma Europe’s managing director. Standardized sales and service processes,<br />

including pre-sales and after-sales support, will provide even faster support<br />

and access to the most up-to-date technologies, solutions and knowledge,<br />

resulting in maximum customer efficiency and performance. The long-term<br />

experience of the employees and management from former precisa CNC-<br />

Werkzeugmaschinen GmbH is particularly important in this regard. “We<br />

are thrilled to be able to rely on their expertise for future growth and new<br />

innovations”, adds Norbert Teeuwen.<br />

further information: www.okuma.eu<br />

Anton Köller, precisa; Sabine Wank, precisa;<br />

Norbert Teeuwen, Okuma (left to right)<br />

An overall positive year for the<br />

italian machine tool manufacturing industry<br />

2023 has been another positive year for the Italian manufacturing<br />

industry of machine tools, robots and automation systems, which<br />

has achieved a new production record, thus extending the favourable<br />

trend that should also be confirmed in <strong>2024</strong>.<br />

This is in short what was outlined by Barbara Colombo, president of<br />

UCIMU- SISTEMI PER PRODURRE, the Italian machine tools, robots and<br />

automation systems manufacturers’ association, during the usual year-end<br />

press conference.<br />

Based on the preliminary year’s data processed by the Studies Dept. &<br />

Business Culture of UCIMU-SISTEMI PER PRODURRE, 2023 production<br />

reached 7,560 mil €, marking a 3.8 % increase over the previous year. The<br />

result was driven by the good performance of exports, which grew by 10.3 %<br />

to 3,825 mil €. The export/production figure went up again, attaining 50.6 %.<br />

On the foreign front, according to UCIMU processing of the data from the<br />

Italian National Statistics Institute (ISTAT), in the period Jan-August 2023<br />

(latest available data), the main destination markets for the Italian product<br />

offering of the sector were the United States (356 mil €, + 26.7 %), Germany<br />

(217 mil €, + 8.8 %), China (163 mil €, + 34 %), France (138 mil €, + 32.1 %) and<br />

Poland (128 mil €, + 14.7 %).<br />

On the other hand, the deliveries by Italian manufacturers in the domestic<br />

market decreased slightly to 3,735 mil €, 2 % less than in 2022. Deliveries and<br />

imports – the latter down by 4.5 % to 2,385 mil € – were affected by the decrease,<br />

however slight, in consumption, which dropped by 3 % to 6,120 mil €.<br />

For <strong>2024</strong> the Italian machine tool, robot and automation manufacturers<br />

expect a consolidation of the results achieved in recent years: production<br />

should be driven by foreign demand, whereas<br />

a moderate reduction should be recorded in<br />

domestic consumption.<br />

According to the forecasts from the Studies<br />

Dept. & Business of UCIMU, <strong>2024</strong> production<br />

should grow to 7,595 mil € (+ 0.5 % compared<br />

to 2023), thanks to the rise in exports, which<br />

should stand at 4,070 mil € (+ 6.4 %).<br />

Deliveries by manufacturers to the domestic<br />

market should not exceed 3,525 mil € (- 5.6 %),<br />

in line with the drop in domestic consumption,<br />

which should reach 5,780 mil € (- 5.6 %).<br />

Imports should also be affected by the<br />

reduced demand for investments in Italy, falling<br />

by 5.5 % to 2,255 mil €. The export/ production<br />

figure should rise again, standing<br />

at 53.6 %.<br />

Barbara Colombo commented: “Although<br />

there are clear signs of a slowdown, the 2023<br />

of Italian manufacturers is closing with a posi -<br />

tive sign; the ‘Made in Italy’ production of<br />

the sector grew again, setting a new record<br />

thanks to the good results obtained by Italian<br />

enterprises abroad”.<br />

further information: www.ucimu.it<br />

no. 1, February <strong>2024</strong><br />


news & facts<br />

Machine tool industry<br />

expecting decline in production<br />

In <strong>2024</strong> the German machine tool industry is expecting production<br />

to decline by almost 3 % to 14.8 bill. € in nominal terms. “A nominal<br />

record volume of 17 bill. € was posted in 2018/2019, and five years<br />

later there is still no sign of this figure being matched,” said Franz-<br />

Xaver Bernhard, chairman of the VDW (German Machine Tool<br />

Builders’ Association), at the association’s annual press conference in<br />

Frankfurt am Main, Germany.<br />

There has been a clear slowdown in orders since the beginning of last year,<br />

which is now having an increasing impact on sales and production. The<br />

considerable order backlog, representing around eleven months’ work, had<br />

helped. However nearly all supply bottlenecks have since been resolved, allowing<br />

the backlog to be worked through more quickly. Accordingly orders<br />

on hand are less and less able to compensate for the lack of new orders. Overall,<br />

orders fell by 10 % in nominal terms in 2023. The decline was partly offset<br />

by several months of stronger project business. Domestic demand fell by<br />

14 %, almost twice as much as foreign demand.<br />

The global economy is unlikely to provide much impetus in <strong>2024</strong>. The<br />

growth rates of both gross domestic product and investment are once again<br />

down on the previous year’s levels.<br />

The international purchasing managers’ index also highlights the weakness<br />

of the global economy in all key markets, particularly in the Eurozone<br />

and Germany.<br />

“In fact, we are currently seeing two divergent developments,” reported<br />

Bernhard. Growth sectors such as electric vehicles, wind power, medical<br />

technology, aerospace and defense boosted the project business in particular,<br />

while the standard machine business performed more weakly. Small and<br />

medium-sized customers such as job shop businesses are uncertain about<br />

the future and are reluctant to invest. Machine purchases are also more difficult<br />

to finance due to higher interest rates. Companies that prepared for the<br />

transformation process at an early stage are therefore better able to weather<br />

the weak demand.<br />

2023 ended with an overall good result<br />

Last year production is estimated to have risen by just under 8 % in nominal<br />

terms, to 15.2 bill. €. In real terms this represents an increase of 2 % due<br />

to inflation, which remained at a high average level over the year. Exports<br />

grew by 9 %. The export ratio reached almost 70 %. Exports were boosted<br />

Franz-Xaver Bernhard<br />

by double-digit growth in America. Asia and<br />

Europe on the other hand, only recorded<br />

single-digit increases. The US in particular<br />

saw extremely dynamic growth, driven above<br />

all by investment in climate protection and<br />

renewable energy. China, by contrast, experienced<br />

weak growth due to falling consumer<br />

demand and the ongoing difficulties in the<br />

real estate sector. India, on the other hand, enjoyed<br />

sharp upward growth. At 5 % domestic<br />

sales did not increase quite as much. This is<br />

attributable in part to the weaker demand<br />

from domestic customers.<br />

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

GLOBAL INDUSTRIE <strong>2024</strong><br />

Paris Nord Villepinte will be the meeting place for the<br />

whole industrial ecosystem March 25-28, <strong>2024</strong>.<br />

As a symbol of reindustrialization, GLOBAL INDUSTRIE<br />

provides companies with concrete solutions by engagement<br />

of bringing together and uniting the whole of industry, its entire<br />

ecosystem, its value chain and its user markets for four<br />

days. With this GLOBAL INDUSTRIE responds to the multiple<br />

challenges facing industry (the environmental and ecological<br />

transition, recruitment, social and societal responsibility<br />

training, financing, industry 5.0, etc.) to ensure that<br />

France remains a land of investment and innovation.<br />

A showcase for regions and know-how, the fair will host<br />

2,300 exhibitors, spread across 15 sectors, all of whom can be<br />

contacts to develop a business and create new synergies with<br />

investors or suppliers in order to build tomorrow’s industry.<br />

Demonstrations and experiments can be seen at the biggest<br />

fair in France with more than 1,500 machines, displaying<br />

cutting-edge innovations and industrial processes, showing<br />

the trends and signals that will transform tomorrow’s industry.<br />

The GI Awards, for their part, will highlight the most<br />

innovative discoveries identified among exhibitors.<br />

further information: www.global-industrie.com<br />

22 no. 1, February <strong>2024</strong>

news & facts<br />

Executive board member<br />

Thierry Wolter retires after 30 years<br />

CERATIZIT has reallocated responsibilities on the<br />

executive board as of December 1, 2023. Following<br />

the planned retirement of executive board member<br />

Thierry Wolter from the operational business, the executive<br />

board will consist of three members in future:<br />

Melissa Albeck, Andreas Lackner and Frank Thomé.<br />

“Thierry Wolter has been one of the defining personalities of<br />

the company over the last 30 years and has made a decisive<br />

contribution to making CERATIZIT one of the world’s largest<br />

carbide manufacturers today,” comments Karlheinz Wex,<br />

chairman of the supervisory board, on Thierry Wolter’s role<br />

in the company’s history. Born in Luxembourg, he was the<br />

most prominent face of the company, particularly in the cutting<br />

tool sector, and represented CERATIZIT nationally and<br />

internationally in numerous organizations.<br />

Wolter sees his entrepreneurial legacy in good hands. “After<br />

30 years it is time to pass the torch to the next generation.<br />

CERATIZIT has come a long way since the merger in 2002<br />

and I am firmly convinced that with the energy, ideas and<br />

commitment of the employees we will succeed in becoming<br />

one of the three largest carbide manufacturers in the world in<br />

the coming years,” says Wolter.<br />

Three executive board members<br />

As part of the ongoing integration of the Plansee Group, the<br />

three CERATIZIT executive board members are also taking<br />

on overarching tasks. For example Andreas Lackner is not<br />

only responsible for production in all CERATIZIT divisions.<br />

As a member of the executive board of the Plansee Group, he<br />

is also responsible for the strategic core topic of sustainability<br />

for the entire Plansee Group.<br />

Melissa Albeck, Andreas Lackner, Frank Thomé (left to right)<br />

Advancing internationalization<br />

Melissa Albeck is now responsible for the sales of cutting<br />

tools, which was previously the responsibility of Thierry<br />

Wolter. She is also responsible for CERATIZIT’s American<br />

business on the executive board. The board trio is completed<br />

by Frank Thomé. His responsibilities include sales for the<br />

hard material solutions and global tungsten & powders divisions<br />

as well as the company’s Asian business, including the<br />

CB-CERATIZIT joint venture.<br />

This gives Albeck and Thomé a key role in the company.<br />

In order to continue to grow faster than the market and become<br />

the number 3 in the carbide industry, it is planned to<br />

focus on growth in Asia and on the American continent in<br />

the coming years.<br />

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

Change in management at VOLLMER KOREA<br />

Sharpening specialist VOLLMER, based in southern<br />

Germany, has appointed a new managing director of<br />

the VOLLMER KOREA subsidiary in Seoul. Jooma<br />

Park assumed the position of managing director from<br />

Song Ho Hwang in spring of 2023.<br />

Song Ho Hwang started working for VOLLMER in South<br />

Korea in the early 1990’s as a dealer under the company name<br />

“Palma Trading”. In 2016, Song Ho Hwang played a major role<br />

in establishing VOLLMER KOREA and was responsible for<br />

the very successful development of the Seoul-based subsidiary.<br />

He retired March 2023.<br />

In Jooma Park an experienced expert and connoisseur of the<br />

Asian tool market is taking over the running of VOLLMER<br />

KOREA. He joined VOLLMER about a year ago and has<br />

shown great commitment in familiarizing himself with his<br />

new position as managing director. At the same time as this<br />

change in management, the<br />

subsidiary also moved into<br />

its new premises in Seoul.<br />

The VOLLMER site in South<br />

Korea employs three people.<br />

“My goal is to sustainably<br />

expand the business of<br />

VOLLMER sharpening machines<br />

in South Korea and<br />

to even more firmly establish<br />

our services and digital<br />

solutions in the tool manufacturing<br />

industry,” says<br />

Jooma Park.<br />

further information:<br />

www.vollmer-group.com<br />

Jooma Park<br />

no. 1, February <strong>2024</strong><br />


news & facts<br />

UNITED GRINDING opens a<br />

subsidiary in Southeast Asia<br />

The UNITED GRINDING Group has been present in<br />

the Southeast Asian region for many years through<br />

representatives and the WALTER EWAG Asia Pacific<br />

subsidiary. Now the specialist for grinding, eroding,<br />

laser and measuring machines bundles and intensifies<br />

its activities in this region by founding a group<br />

subsidiary in Singapore, United Grinding Asia Pacific<br />

Pte. Ltd.<br />

“Southeast Asia is a strategically very crucial region for us.<br />

Establishing a UNITED GRINDING subsidiary is the logical<br />

step to intensify our activities in this region,” explains<br />

Stephan Nell, CEO of the UNITED GRINDING Group.<br />

The potential is high, and the number of customers is continuously<br />

increasing. “Proximity to our customers has always<br />

been important to us to ensure fast and uncomplicated<br />

support,” adds Nell. The ability to offer the group’s bundled<br />

technology and application know-how from a single<br />

subsidiary offers customers<br />

many advantages.<br />

Michael Schmid, CEO of the<br />


branch and already responsible<br />

for the Southeast Asian<br />

business of the WALTER and<br />

EWAG brands for more than<br />

20 years, adds: “We can bundle<br />

the strength of our powerful<br />

team in the joint group<br />

Michael-Schmid<br />

subsidiary and serve our customers even better. In the future,<br />

we will offer all three group technologies, surface and profile<br />

grinding, cylindrical grinding and tool machining, under<br />

one roof. I am convinced that bundling and intensifying our<br />

activities in this region is a win-win for all parties involved.”<br />

further information: www.grinding.ch<br />

Unlocking sustainable advantages<br />

Harnessing solar power for a green future<br />

Weiler Abrasives, a global provider of abrasives,<br />

power brushes and maintenance products for surface<br />

conditioning, is thrilled to announce a major leap toward<br />

sustainability with the initiation of two photovoltaic<br />

systems at its Maribor and Zreče manufacturing<br />

facilities, commencing operations in October 2023.<br />

These photovoltaic systems represent a significant commitment<br />

to harnessing clean, renewable solar energy, aligning<br />

with Weiler Abrasives’ dedication to environmental responsibility<br />

and sustainability. The installation is designed to contribute<br />

up to a fifth of Weiler Abrasives’ electricity requirements<br />

in its Slovenian facilities and, as a result, decrease<br />

nearly 900 tons of CO 2 emissions annually through climatefriendly<br />

solar energy.<br />

“The combined output of this impressive 1,839 kWp solar<br />

power installation is remarkable, generating electricity equivalent<br />

to the demand of around 1,000 households. This initiative<br />

significantly reduces greenhouse gas emissions, equivalent<br />

to removing 500 medium-sized cars from the road annually,”<br />

explains Rok Mezgec, director – supply chain and<br />

R&D at Weiler Abrasives. “As a founding member of the<br />

Sustainable Abrasives Association of Europe (SEAM), Weiler<br />

Abrasives is committed to the industry’s shared goals on<br />

three key pillars of sustainability: environment, society and<br />

business. By implementing this project our company is putting<br />

sustainability at the forefront and recognizing it as a<br />

competitive advantage in the industry.”<br />

Jože Kaligaro, managing director of Weiler Abrasives<br />

EMEA, commented on the importance and strategic significance<br />

of the systems in place.<br />

“The project of constructing the photovoltaic systems is<br />

undoubtedly of particular importance in the implementation<br />

and strengthening of the sustainable development activities<br />

of the Weiler Abrasives Group, especially because of<br />

the economic and environmental impact it brings and the<br />

knowledge and experience that our teams of experts have acquired<br />

in its implementation. The latter means forming new<br />

development nuclei for the search and implementation of<br />

the sustainable projects that lie ahead. It is already clear that<br />

in the future the successful implementation of sustainable<br />

projects will be the key point of differentiation between<br />

successful and unsuccessful companies in the long term,”<br />

Kaligaro says.<br />

“At Weiler Abrasives we believe that it is our responsibility<br />

to take meaningful steps toward mitigating our environmental<br />

impact. The introduction of these photovoltaic systems<br />

marks a significant milestone in our sustainability journey,”<br />

states Arjang “AJ” Roshan-Rouz, Weiler Abrasives CEO, at<br />

the official launch of the systems. “By embracing renewable<br />

energy solutions, we not only reduce our carbon emissions<br />

but also demonstrate our dedication to fostering a cleaner,<br />

more sustainable future for our community and the planet.”<br />

Weiler Abrasives remains steadfast in exploring further<br />

opportunities to minimize its environmental footprint,<br />

embracing innovative technologies and sustainable practices.<br />

Implementing these photovoltaic systems reflects the com<br />

pany’s dedication to sustainability and environmental responsibility,<br />

embodying the company’s commitment to making<br />

a positive difference in the world.<br />

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

24 no. 1, February <strong>2024</strong>

MAPAL Group mourns Dr. Dieter Kress<br />

news & facts<br />

Dr. Dieter Kress passed away<br />

on December 27, 2023, at the<br />

age of 81 after a long illness.<br />

He was a passionate entrepreneur<br />

and an impressive personality.<br />

Dr. Dieter Kress was<br />

at the helm of the MAPAL<br />

Group for almost five decades.<br />

He shaped the once small company into an international<br />

company group. 2018 he retired from active management, but<br />

continued to take a lively interest in the company’s developments.<br />

“MAPAL is my baby and that’s why I will never let it<br />

out of my sight completely,” he once said. The entire workforce<br />

joins the Kress family in mourning the passing of Dr.<br />

Dieter Kress.<br />

Dr. Dieter Kress joined MAPAL Dr. Kress KG in 1969<br />

after graduating with a degree in mechanical engineering<br />

and business administration. His father Dr. Georg Kress had<br />

founded the company in 1950. While working at the company,<br />

Dr. Dieter Kress completed his doctorate on the subject of<br />

reaming, which was the basis for the success story of MAPAL.<br />

Dr. Dieter Kress developed high-performance special tools<br />

from the standard reamer product. This also became the<br />

essence of MAPAL – always close to the customer to find the<br />

best solution for him and his machining.<br />

With great vision and personal commitment Dr. Dieter<br />

Kress managed the company for 49 years as president. The<br />

product portfolio was continuously expanded under his leadership<br />

and MAPAL established itself on the market as a fullrange<br />

supplier. Tools for drilling, countersinking, milling,<br />

hard turning and boring were added to the reaming range.<br />

Chucks and devices for setting, measuring and dispensing<br />

as well as numerous tool-related services further expanded<br />

the portfolio.<br />

In addition, company acquisitions and foundations were<br />

responsible for MAPAL’s enormous growth. Dr. Dieter Kress<br />

followed his very own strategy. For him it was important to<br />

respect and preserve the respective culture of the acquired<br />

companies. In his 49 years at the helm, Dr. Dieter Kress<br />

transformed a regionally active manufacturer of taps into an<br />

internationally active, broadly positioned company group.<br />

Dr. Dieter Kress<br />

Today, MAPAL is represented in<br />

44 countries and employs around<br />

5,000 people worldwide, including<br />

around 1,700 at headquarters<br />

in Aalen. In 2018 Dr. Dieter Kress<br />

handed over responsibility to his<br />

son Dr. Jochen Kress, who is now<br />

the third generation to run the<br />

precision tool manufacturer.<br />

In addition to his entrepreneurial activities Dr. Dieter Kress<br />

was also involved in a number of honorary positions. The<br />

region and the training of young people were particularly<br />

close to his heart. He attached great importance to training<br />

junior staff directly at MAPAL and invested in the corresponding<br />

infrastructure. Today MAPAL is one of the largest<br />

training companies in the East Württemberg region. There<br />

are as many as 300 apprentices at MAPAL worldwide, about<br />

130 learning different professions at MAPAL in Aalen – from<br />

cutting machine operators to warehouse logistics specialists<br />

and IT specialists.<br />

Dr. Dieter Kress also supported research and education at<br />

the Aalen University – among other things by setting up an<br />

endowed chair in cooperation with other companies and as<br />

a member of the university council. He was active in committees,<br />

initiatives and associations, including as chairman<br />

of the VDMA Precision Tools Association and as a founding<br />

member of the P.E.G.A.S.U.S. association, which supports<br />

company founders.<br />

Dr. Dieter Kress has received numerous awards for his services,<br />

including the Cross of the Order of Merit of the Federal<br />

Republic of Germany and the Golden Staufer Medal of the<br />

state of Baden-Württemberg. He was also one of the first recipients<br />

of the German Mechanical Engineering prize. Aalen<br />

University confer him the dignity of honorary senator.<br />

The MAPAL Group and its employees owe a great deal to<br />

Dr. Dieter Kress. He has shaped, developed and promoted the<br />

company and its employees as the driving force and motor.<br />

It is with great gratitude and deepest sympathy for his<br />

family that the shareholders, management, works council<br />

and employees take their leave.<br />

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

no. 1, February <strong>2024</strong><br />


news & facts<br />

LACH DIAMANT – 100 Years<br />

Tradition. Passion. Innovation.<br />

part 8:<br />

It was only this little spark that brought<br />

the cutting world to its current glory…<br />

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

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

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

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

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 multiple<br />

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

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 />

Just recently, you have accompanied me on my search for the ultimate method<br />

for cutting/forming of polycrystalline diamonds (see part 7 – hp tooling, 2023,<br />

#4). We succeeded. The “spirit in a bottle” was able to escape as a tiny little<br />

spark. On the same day, only hours later the patent was registered.<br />

A new and exciting era of the industrial use of diamonds began; thanks<br />

to the durability of diamonds, the now possible serial production of tools,<br />

and due to the use of robots in the automotive and supply industries, wood<br />

and furniture industry, airplane, wind energy and composite industries and<br />

thanks to many other factors. Aluminum and materials like glass and carbon<br />

fibers, all difficult to process, were now under control; electro-graphite<br />

carbon and, for example, ceramic and carbide in its green state could now<br />

be processed much more efficiently. It was like looking into a black hole,<br />

while gaining new and surprising insights and finding new solutions on a<br />

daily basis.<br />

LACH-EDGplus® (Electrical Discharge<br />

Grinding) process for spark grinding of polycrystalline<br />

cutting materials, PCD and PCBn<br />

European Patent No. 0 010 276<br />

Method and device for electroerosive machining synthetic polycrystalline<br />

diamond and use of the diamonds machined according to this method.<br />

Priority: October 13, 1978 – granted and published April 21, 1982<br />

Patent claims (excerpt):<br />

1. Method for electroerosive machining synthetic polycrystalline diamond,<br />

characterized in that for producing arbitrary profiles the machining is made<br />

by means of spark erosion.<br />

2. Polycrystalline synthetic diamond produced according to claim 1,<br />

characterized in that the synthetic polycrystalline diamond machined by<br />

spark erosion shows the profile of a circular disc or a circle section or a<br />

circular ring or a circular ring section or a rectangle or an ellipsis section or<br />

of a form composed of these configurations.<br />

3. Use of synthetic polycrystalline diamonds machined by spark erosion as<br />

cutting edges in single or multiple-cut rotary tools, preferably for machining<br />

of hardwood or synthetic resin sheets or particle boards.<br />

Diagram of spark erosion grinding with<br />

rotating electrode, either graphite or copper<br />

26 no. 1, February <strong>2024</strong>

news & facts<br />

Application examples –<br />

250-350 times superior durability compared to carbide<br />

While I am writing this, November 2023, I begin to ponder.<br />

Dreams of the future? An article in the german magazine<br />

“Der Spiegel” (no. 39) on the “Magic of ice clouds” which lead<br />

to diamond rain on the planet Neptune surprises me. On<br />

earth the so-far largest diamond found weighed only 600 g,<br />

equal to 3,000 carat (1 g = 5 carat). Scientists are already specu -<br />

lating that diamond blocks measuring several meters, if not<br />

kilometers, could exist in the inside of the icy giant Neptune.<br />

A task for the year 2088 when the first returning space robots<br />

present diamond blocks to us. A task for our little spark?<br />

Well, we still have to discuss the years after 1979 which, have<br />

been and will continue to be exciting.<br />

The stuff that dreams are made off<br />

The first results from polycrystalline diamond-tipped profile<br />

cutters, made for the company Resopal, for use on double-<br />

end profilers, were – for us (me), and for the crew of Resopal –<br />

something like the stuff that dreams are made off. Little by<br />

little we realized that we had made a momentous discovery.<br />

The tool life of diamond tools, produced with the help of the<br />

“little spark,” had levelled off at 250 to 350 times that of the<br />

previously used traditional carbide tools.<br />

Until then the technicians/foremen already had to change<br />

carbide tools after one shift, and for that reason they had to be<br />

present through the third shift – they were more than happy<br />

about the extended durability of diamond tools.<br />

At the start of January 1979, during my initial phase of<br />

euphoria, I asked my father how we should proceed with<br />

this development. I will never forget his answer: “I am now<br />

85 years old, if you want to do this, you are welcome to”.<br />

PCD diamond profile milling tool on<br />

double-ended profiler (unilateral view), 1979<br />

Diamond milling tools cutting wood<br />

and plastic materials<br />

no. 1, February <strong>2024</strong><br />


news & facts<br />

After examination, a diamond profile<br />

milling cutter was marked “BG-Form”<br />

back then – today “BG-Test”<br />

The first certified<br />

dia profile milling cutters<br />

according to “BG-Test”<br />

dreboquick® – a good idea,<br />

unfortunately not feasible; it failed due to<br />

imprecise fittings for the inserts<br />

This signaled the start for the foundation of the company<br />


established as Ltd. in February 13 th , 1979, at my friend<br />

Gerhard Grossmann’s notary’s office in Frankfurt.<br />

Do it<br />

Even in retrospect, at that time it was a good recommendation<br />

of my father to separate the new company<br />

“LACH-SPEZIAL” from the existing LACH DIAMANT<br />

company, which was more closely connected to the metalworking<br />

industry, with the goal to win customers in the<br />

wood and plastics industry. Luck was an additional factor,<br />

since the AiF (German Federation of Industrial Research<br />

Associations) had just started an aide programe for small<br />

and medium-sized start-up companies, and they had established<br />

company-specific assistance measures. The project<br />

“Diamonds cut wood and plastic”, launched upon the foundation<br />

of LACH-SPEZIAL, could take off.<br />

We hired employees, purchased the first machines – one<br />

of them a wire EDM machine – and our R&D work as well<br />

as our search for new customers could begin. The question<br />

being, who needs LACH-SPEZIAL tools for all wooden<br />

materials?<br />

In short and simply put, you could answer this question<br />

today with: “Look it up on the internet”. However back<br />

then, 1979, we did have publications like “Who supplies<br />

what”, “ABC of the german economy” and also tradeshows<br />

with a special focus on wood as raw material. One example:<br />

LIGNA, an international trade fair for woodworking and<br />

wood processing.<br />

The world’s first presentation of diamond tools for<br />

plastic and wood machining at LIGNA 1979 in Hanover<br />

28 no. 1, February <strong>2024</strong>

news & facts<br />

Another way how diamond tools for wood and<br />

plastic machining were presented at LIGNA 1979<br />

One of the first dreborid® D profile steels for<br />

aluminum processing, produced with the “little spark”<br />

So LIGNA 1979 in Hanover was selected for the first<br />

presentation of “Diamonds for all wood materials” by<br />

LACH-SPEZIAL-WERKZEUGE GMBH. It was a good thing<br />

that LACH DIAMANT had already booked a large peninsula<br />

booth there. Now, the “cat was out of the bag” – the<br />

secret of our LACH specialists, so long kept behind closed<br />

doors, was finally out.<br />

To the surprise of all, especially the suspiciously observing<br />

manufacturers of woodworking tools at that time, the team<br />

of the first hour had succeeded in presenting a complete portfolio<br />

of diamond tools, analog to the available carbide tools<br />

for milling, scoring, cutting, and sawing etc.<br />

The idea to fit commercial, exchangeable carbide inserts for<br />

milling cutters with diamonds had to be discarded. First attempts<br />

with dreboquick® PCD inserts, custom-made for this<br />

project, quickly brought to mind the abrasiveness and durability<br />

of our chosen diamond cutting material! The tolerances<br />

of the available milling cutters were so variable and large<br />

that the installed dreboquick® cutting inserts would create<br />

unclean milling marks which would not equalise, even after<br />

extended use, like carbide; typical for diamond!<br />

This insight led to a problem for the new production. No<br />

removable inserts for the wood-milling cutters meant soldering!<br />

Apart from the diamond-depreciating statement “Lach<br />

has gone insane – now he wants to cut wood with diamonds”,<br />

now rumors were spread that the diamonds soldered onto<br />

milling bodies were “dangerous for life and limb” because<br />

they would get loose at high speeds. Well, even this claim did<br />

not impede the triumphant success of diamond for all wood<br />

materials and of course for aluminum etc. also. As a side<br />

note: these soldered milling cutters were the forerunners of<br />

the “Monoblock” milling cutters later used in metal working.<br />

A triumphant success begins<br />

Customers invited to the LIGNA exhibition booth, and first<br />

diamond tool users were so enthusiastic that trade press<br />

reporters, present at the event, announced a “Diamond era”.<br />

Space for LACH-SPEZIAL at LACH DIAMANT’s facilities<br />

became increasingly cramped. Jakob Lach, now 85 years old,<br />

still followed the developments with great interest and pride,<br />

and he knew what to do. A locksmith’s shop, not far from<br />

our headquarters at Bruchköbeler Landstrasse in Hanau,<br />

Germany, and space at the already transferred production facility<br />

for diamond and CBN grinding wheels were available<br />

for a move in August.<br />

Only a few weeks afterwards, September 1 st , 1979, three<br />

employees started work at – what was now called – “LACH<br />

Group”. During the following years they would make<br />

their impact on LACH DIAMANT and LACH-SPEZIAL:<br />

Edgar Schneider, later the product manager for diamond<br />

dressing tools and electroplating of diamond and CBN abrasives,<br />

Horst Köllner (✝) as grinding specialist and application<br />

technician, and for LACH-SPEZIAL Dieter Claus, a former<br />

helicopter mechanic, who would later dedicate his special<br />

talents to development, application, and sales of diamonds<br />

for cutting wood and plastics.<br />

It was time to add new employees to the young<br />

LACH-SPEZIAL team in order to accelerate their success,<br />

such as Achim Weber, later facility manager, and freshlyhired<br />

Günther Pallischeck and Heinz Katta, with the result<br />

that diamond tools became indispensable for the wood and<br />

furniture industry.<br />

Many new ideas, also outside of the prevailing school of<br />

thoughts, were now implemented and introduced to different<br />

industries. In the meantime, independent of the developments<br />

at LACH-SPEZIAL, the “little spark” had also gained<br />

importance at LACH DIAMANT. Wire EDM machines were<br />

used as well as sinking machines with profile electrodes.<br />

And now machines<br />

Speaking of electrodes for sinking EDM machines; a former<br />

employee, Gerhard Mai, recently reminded me how, at that<br />

time, I had once observed this machining process in detail;<br />

the copper electrode had to be polished after each use,<br />

no. 1, February <strong>2024</strong><br />


news & facts<br />

which was especially time-consuming for profiled electrodes. Apparently,<br />

after studying the process, I suddenly said: “What if we could bend this electrode<br />

round?” This was basically the invention of “spark grinding” with profiled,<br />

rotating graphite or copper wheels, also known as “EDG grinding<br />

process (electrical discharge grinding), and its neologism “EDG-plus” is<br />

today one of our protected trademarks. I had completely forgotten about<br />

this; I should have filed a patent application…<br />

“But not to worry, Horst Lach” – since this was the start of machine building<br />

for LACH DIAMANT at the same time. First for our own use, and later<br />

also for sale to service grinding shops and other diamond tool manufactures.<br />

Until today CNC-controlled EDG-plus rotation grinding machines for<br />

“contactless” grinding of polycrystalline diamond tools and saws, drills, and<br />

other similar tools, are manufactured and sold worldwide.<br />

A report in hp tooling, 2021, #4 (“Poly, poly or what? 10 th part – When sparks<br />

learned to fly on diamonds”) gives an account of the development of versatile<br />

new models and applications. Today our top model is the “Dia-2200-mini”<br />

for ultimate service and manu facturing of diamond tools and saws.<br />

Advancing development<br />

If I may say so, the size of polycrystalline diamonds kept up with the<br />

expansive development of the LACH group. During LIGNA times the<br />

available PCD inserts had just about 0 8.1 mm then; but only a few months<br />

later already 0 13.2 mm. Through continual contact to the manufacturer<br />

General Electric, and here especially to Louis Kapernaros (✝), who was welldisposed<br />

to our efforts, I tried to advance the development. You can easily<br />

imagine how manufacturers of PCD tools had to do without the “little spark”<br />

until 1978, and for that reason only tools with soldered-on diamonds were<br />

available, as for example turning tools. With the now possible variety of<br />

milling tools and saws, more and more diamonds per piece were needed. A<br />

chance for GE to invest in presses and therefore larger PCD inserts – meaning<br />

for LACH better purchase prices, and therefore greater efficiency for our<br />

customers.<br />

Dia-2200-mini, universal CNC spark grinding machine for<br />

diamond milling cutters, hoggers and saws up to 0 600 mm<br />

First beginnings of LACH SPEZIAL production,<br />

under management of Achim Weber (photo)<br />

and Dieter Claus<br />

Among the many events of the years 1979/80<br />

one stands out. Around February 1980, Dieter<br />

Claus appeared in my office, apparently very<br />

excited. “There are two gentle men out there<br />

who want to build a special machine for machining<br />

circuit boards – what should I tell<br />

them?” I reminded him of an old catalogue<br />

from 1976/77, featuring images of simple<br />

PCD milling tools and the like, and our collective<br />

experiences during productronica<br />

1977. The result being that both gentlemen<br />

were enthusiastic about the possibility, thanks<br />

to the little spark, to now use PCD efficiently<br />

for machining circuit board materials such<br />

as fiberglass boards. By the way, the visitors<br />

were Mr. Löhr and Mr. Herrmann who later,<br />

very successfully, built a machine of the same<br />

name based on their concept of “multi-layer<br />

machining”. Thereby PCD had conquered a<br />

new industry, a new sector: machining of circuit<br />

boards.<br />

The story will continue, even internationally,<br />

in our next 100-year anniversary article.<br />

Yours, Horst Lach<br />

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

30 no. 1, February <strong>2024</strong>

processes<br />

Extreme surface finish for e-mobility<br />

Particular precision and process reliability have<br />

characterized automotive engineering for many decades.<br />

With the establishment of e-mobility, however, these<br />

demands are increasing once again, because many<br />

e-motor components need to be manufactured even<br />

more “perfectly”. In most cases this involves the highest<br />

surface finish in the micrometer range so that no<br />

loud running noises occur on the gear components. In<br />

a quiet e-motor, for example, these noises would be<br />

audible. In this context, the technology of EMAG SU<br />

is drawing the attention of many production planners.<br />

Among other things, the specialists developed high-performance<br />

solutions for gear grinding – including short chip-tochip<br />

times, intelligent axis concepts, thermal and mechanical<br />

stability and a high degree of user-friendliness. Which<br />

machines and processes are the focus here?<br />

Outstanding solutions for the field of gear profile grinding<br />

include the G 250 machine on the one hand and the G 160<br />

on the other. The G 160 is used for components up to module<br />

three and with a maximum O/D (outer diameter) of 160 mm.<br />

In this field of application it is the fastest machine on the<br />

market, made possible by two parallel workpiece tables that<br />

move alternately at high speed to the grinding wheel. Thus,<br />

while one component is machined, the internal loading robot<br />

inserts a blank into the other spindle or unloads the beforehand<br />

finished component. Additionally the axis concept<br />

ensures perfect surfaces, which are so important in e-mobility.<br />

The decisive factor here is that the G 160 does not have a<br />

tangential axis, but instead the existing Y- and Z-axes generate<br />

a “virtual” tangential axis through simultaneous movement.<br />

As a result the distance between the A-axis and the<br />

tool contact point is very small, which in turn prevents the<br />

so-called “ghost frequencies” on the surface of the component.<br />

The possibilities this approach opens up for e-mobility<br />

are shown by the example of an “intermediate shaft” with<br />

21 teeth and a normal module, where a floor-to-floor time<br />

of only 33 s (including entanglement compensation and proportional<br />

dressing time) and a grinding time of only 25 s are<br />

achieved. Similar performance values are shown for an input<br />

shaft with 26 teeth and a module of 1.6 mm. Here the pure<br />

grinding time is only 28 s.<br />

Minimum floor-to-floor times<br />

The larger G 250 machine also scores with precision, minimum<br />

chip-to-chip times, short setup times and reliability<br />

for components with a maximum length of 550 mm. The<br />

machine has also a double table (like the G 160). Loading and<br />

unloading operations as well as component measurement<br />

are thus performed in cycle time-concurrently. Additionally<br />

the grinding mandrel can accommodate grinding wheels<br />

with different diameters, and the entire design is very rigid.<br />

Gear generating grinding and profile grinding take place on<br />

the main grinding spindle, so the machine does not have a<br />

thermal growth. It can also be retooled for the other process<br />

in just a few minutes. In the field of e-mobility, for example,<br />

The G 250 (like the G 160) also has a double table,<br />

loading, unloading and measuring of the<br />

components thus takes place in<br />

cycle time-concurrent<br />

this approach is used for grinding axle drive wheels. The<br />

floor-to-floor time here is only 69 s (including entanglement<br />

compensation and proportional dressing time), with the<br />

actual grinding time comprising only 58 s. The G 250<br />

achieves a comparably high productivity level when machining<br />

pinions with a strong crowning in the tooth flank profile<br />

and normal crowning in the flank line. The bottom-to-bottom<br />

time is 33 and the grinding-only time is 28 s. A DIN 3962<br />

quality of 4 is achieved.<br />

Sky-Grind: signigicantly lower costs<br />

Furthermore EMAG SU illustrates what the general future<br />

of gear grinding could look like with the establishment of<br />

the new “Sky-Grind” process. Here the final grinding on<br />

the gear is carried out completely dry – with great financial<br />

advantages for the users, because the filter system, cooler<br />

and co. (which are normally required for wet grinding) are<br />

no longer needed, thus reducing the initial investment. In addition,<br />

energy consumption is massively reduced. The whole<br />

thing is made possible by a dual-tool system with two different<br />

tool spindles in the machine: one for finish-machining by<br />

hobbing and one for finish-machining by grinding. In practice,<br />

this means that, in the case of the classic automotive<br />

gearwheel with 100 µm allowance per flank, the Sky-Grindprocess<br />

removes 90 µm by hobbing and only 10 µm by gear<br />

generating grinding. In the end, the cycle times of conventional<br />

wet gear grinding and the Sky-Grind process are very<br />

similar; however, the costs are very different.<br />

How can EMAG SU’s know-how and offers be summarized?<br />

“You could certainly say that we guarantee our customers<br />

competitive advantages and a fast return in investment,”<br />

answers Alexander Morhard from EMAG SU. “To this<br />

end we continuously invest in research and development to<br />

further increase the efficiency and environmental friendliness<br />

of the machines. The result is perfect solutions for the<br />

production of ultra-fine surfaces with different contours.”<br />

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

no. 1, February <strong>2024</strong><br />


processes<br />

High-end surfaces of gears for electromobility<br />

written by<br />

Janis Thalau and Dr.-Ing. Philip Geilert,<br />

technology testing/fundamentals, KAPP NILES GmbH & Co. KG<br />

Introduction<br />

While the quantity of gears within drive trains for e-mobility has drastically<br />

decreased compared to drive trains for vehicles with combustion engines,<br />

their design has changed significantly and alongside the geometrical tolerances<br />

were massively sharpened. The reasons for this are twofold: with the<br />

omission of the noise emission of the motor, the gear boxes acoustic behavior<br />

moved into focus. Furthermore the range of electric vehicles became an important<br />

selling argument, which is why the transmission efficiency of drive<br />

trains gained in importance considerably.<br />

New requirements and challenges<br />

There are a number of changes in requirements with regard to the drive components<br />

of electric vehicles:<br />

• Reduction of noise emissions<br />

Due to the elimination of masking noise from an internal combustion<br />

engine, noise emissions from the transmission can dominate in the<br />

low speed range.<br />

• Higher loads<br />

The gears in the transmission of electric vehicles are under different<br />

and potentially higher loads, as they generally only have one gear (and<br />

two gear stages). In addition electric motors have a different speed/<br />

torque curve (already high torques at low speeds).<br />

• Higher efficiency<br />

The efficiency of an electric motor is significantly higher than that of<br />

an internal combustion engine. This contributes to the great relevance<br />

of the transmission’s efficiency.<br />

• Complex contact mechanisms<br />

In order to meet the above-mentioned requirements, the different<br />

mechanisms occurring during the gear tooth contact within the<br />

transmission must be considered. These include the material fatigue,<br />

excitation and tribological behaviour of the gear pair. These contact<br />

mechanisms are influenced by the shape deviations of different orders<br />

(1 st order: form deviation, 2 nd order: waviness,<br />

3 rd & 4t h order: roughness, 5 th order: microstructure).<br />

• Lightweight construction<br />

In order to be able to map the high speed<br />

ranges of transmissions for e-mobility<br />

drive trains, lightweight construction<br />

of gears becomes more common.<br />

This results in challenges with regard<br />

to heat treatment related distortions<br />

as well as workpiece clamping.<br />

• New measuring values<br />

In roughness measurement, “new”<br />

characteristic values are increasingly<br />

being used, some of which are only<br />

defined by factory standards.<br />

Achievable quality by<br />

different finishing technologies<br />

The consequent increase in demand for<br />

smoother surfaces on tooth flanks leads to<br />

a wider use of surface finishing technologies<br />

such as fine grinding or polish grinding.<br />

While surfaces manufactured by fine grinding<br />

still exhibit a structure comparable to conventionally<br />

ground surfaces but with a much<br />

lower amplitude, polish ground surfaces almost<br />

entirely lack roughness peaks.<br />

New requirements and challenges regarding gear grinding for EVs<br />

Factors influencing the optimisation strategies<br />

32 no. 1, February <strong>2024</strong>

processes<br />

Grinding of an e-mobility shaft with a combined grinding worm<br />

Waviness analysis on a KNM 2X measuring machine<br />

Challenges of polish grinding technology<br />

The distinctive structure of polish ground surfaces is caused<br />

by the elastic nature of the often used polyurethane-bound<br />

grinding tools. While the structure of the surfaces manufactured<br />

with these tools seems to be preferable in comparison<br />

to fine grinding, the elastic behavior of the tools poses great<br />

challenges for meeting the tighter tolerances regarding form<br />

deviations. Geometrical effects such as dents, rounding of the<br />

tooth tip, constrictions around the tooth root or waviness are<br />

typical for polish grinding.<br />

Adapting the polishing pressure can improve the surface<br />

quality and reduce geometric anomalies. While a reduction<br />

of the center distance between tool and workpiece leads to<br />

a global increase in polishing pressure, it is often necessary<br />

to modify the polishing pressure in a local manner to avoid<br />

the mentioned geometric anomalies. Furthermore the quality<br />

of the ground tooth flanks, which represents the initial<br />

condition of the polishing process, must never be left unconsidered<br />

in the design of the polish grinding process or when<br />

analysing geometric deviations.<br />

Challenges of measurement technology<br />

Achieving new levels of surface quality while also meeting<br />

the requirements regarding form deviations does not only<br />

challenge manufacturing technology but is also demanding<br />

in regard to measurement technology. In this context, conventional<br />

values for describing surface roughness such as<br />

Ra and Rz as well as form deviations such as ffα and ffβ lose<br />

their significance. Therefore, values derived from the Abbott-<br />

Firestone curve for surface description and waviness analyses<br />

come to the fore when characterizing the quality of gearboxes<br />

for electromobility.<br />

Optimization strategies by KAPP NILES<br />

In the past years KAPP NILES has developed several strategies<br />

as to how machine, software, tool and process design<br />

must be adapted to reach an optimal balance between productivity,<br />

surface quality as well as form deviations. In this<br />

context, e. g. dressing tool design as well as dressing technology,<br />

new correction options within the machine software or<br />

optimization of the dynamic behavior of machines as well as<br />

drives and axes can contribute to fulfill the ambitious quality<br />

requirements for gears in e-mobility.<br />

Janis Thalau<br />

technology testing/<br />

fundamentals<br />

Process design for<br />

polish grinding<br />

Dr.-Ing. Philip Geilert<br />

technology testing /<br />

fundamentals<br />

further information: www.kapp-niles.com<br />

no. 1, February <strong>2024</strong><br />


processes<br />

Benefit from tried-and-tested grinding technology<br />

Contract manufacturers in particular must be able<br />

in trusting completely in the technologies, machines,<br />

and processes they use. Only then can they manufacture<br />

one-off and small-batch components with extreme<br />

precision and process reliability. That’s why<br />

Ingold Tools AG, a well-known precision manufacturer,<br />

relies on CNC cylindrical grinding machines from<br />

STUDER.<br />

Christoph Jenzer, managing director at Ingold Tools in<br />

Inkwil, proudly states that his production specialists have<br />

had excellent experiences with STUDER cylindrical grinding<br />

machines for many years. “Even on an old grinding machine<br />

that has a belt drive and is close to being an antique<br />

itself, our experts were able to achieve exceptional roundness<br />

accuracy and superior surface quality on the machined<br />

workpieces. The outstanding quality of STUDER’s grinding<br />

machines has continuously impressed me for many years.”<br />

As Christoph Jenzer puts a high premium on reliable technology,<br />

he consistently invests in tried-and-tested grinding machines.<br />

“As in the past, the quality of a grinding machine continues<br />

to be determined by whether it has a stable and fully<br />

settled platform. That’s why, up to now, we have exclusively<br />

procured grinding machines that have already proven themselves<br />

over several years. Naturally this is very advantageous<br />

from an economic perspective,” he explains. After annual<br />

investments starting in 2014, the manufacturing facility in<br />

Inkwil now boasts eight STUDER CNC cylindrical grinding<br />

machines.<br />

Reliably leak-tight: using an S21 cylindrical grinding machine<br />

retrofitted with a motor spindle for internal and thread<br />

grinding, Ingold Tools accurately machine bores and<br />

control slots in valve housings with a precision<br />

of 2 μm (0.000,080 '')<br />

Reliably leak-tight:<br />

After control pistons<br />

have been milled,<br />

drilled, pre-turned<br />

and coated with hard<br />

plastic, they undergo<br />

precise grinding on a<br />

STUDER cylindrical<br />

grinding machine to<br />

achieve a diameter<br />

accuracy of 2 μm<br />

(0.000,080 '')<br />

Comprehensive range clinched the deal<br />

Christoph Jenzer’s preference for cylindrical grinding machines<br />

from Thun-based STUDER is also rooted in the large<br />

variety offered by this manufacturer. “At STUDER, we always<br />

find the machine needed for our comprehensive range of<br />

components,” he says. For example the contract manufacturer<br />

now machine workpieces ranging from 0 around 10 mm to<br />

450 mm (0.4 to 17.7 '') and 1,6 mm (63 '') in length on STUDER<br />

machines like the S21, S31, S33, S40 and S41. First the manufacturer<br />

had all the machines overhauled by the overhauling<br />

department of STUDER. On some of them, additional machining<br />

capabilities were added. This was the case, for example,<br />

with an S21 cylindrical grinding machine on which<br />

internal and thread grinding as well as in-process gauging<br />

for adaptive grinding had been added. As Christoph Jenzer<br />

emphasizes, the manufacturer always provided comprehensive<br />

support for the overhauls, with qualified service and<br />

readily available spare parts. Claudio Delmenico, area sales<br />

manager at STUDER, adds: “Even with grinding machines<br />

tried and tested over many years, we ensure that manu -<br />

facturing companies can benefit from the advantages of our<br />

technology. This includes consulting, service, technical information<br />

and spare parts, not only for the mechanical systems<br />

and drive technology we developed but also for the control<br />

technology and software.” Christoph Jenzer confirms the service<br />

personnel at STUDER being highly responsive and dependable.<br />

One always has prompt access to competent contact<br />

persons and qualified information, enabling reliable<br />

grinding even on tried-and-tested machines.<br />

Accurate to the micron<br />

The manufacturing engineers at Ingold Tools achieve exceptional<br />

precision by combining their know-how, acquired<br />

over many years, with the tried-and-trusted CNC grinding<br />

machines. As an example, Christoph Jenzer cites bearing<br />

covers for motor spindles used in high-speed machining.<br />

At Ingold Tools they first undergo turning and milling<br />

34 no. 1, February <strong>2024</strong>

processes<br />

Complete machining: through turning and milling operations<br />

and a final grinding process, Ingold Tools carries out the<br />

complete production of bearing covers for motor spindles<br />

used in high-speed machining<br />

Christoph Jenzer (Ingold Tools) chats with Claudio Delmenico<br />

(area sales manager at STUDER) left to right;<br />

Ingold Tools benefits from the outstanding characteristics<br />

of proven STUDER cylindrical grinding machines<br />

operations, followed by cylindrical grinding on the external<br />

and internal diameters, with a precision of up to 2 μm<br />

(0.000,080 '') in the position form, and dimensional accuracy.<br />

Christoph Jenzer explains: “In grinding, the pre-machining<br />

also determines whether the desired and required accuracy<br />

can be achieved. Therefore we prefer to machine difficult<br />

and complex components in-house, from the blank to<br />

the high recision finished workpiece. With this we of course<br />

position ourselves as competent partners for precision manufacturing<br />

for our customers.” On select components the specialists<br />

in Inkwil are even able to achieve a high polish finish<br />

through a process called lap grinding. Thanks to this<br />

outstanding performance, Ingold Tools AG has established<br />

a strong presence in multiple industries, including drive<br />

technology, machinery and special-purpose machines, hydraulics<br />

and clamping technology. For the latter mentioned,<br />

Known for precision<br />

Founded in 1946 as a supplier to the machine tool industry,<br />

Ingold Tools AG initially produced mainly punching tools,<br />

gauges, jigs, injection nozzles, and special bearings and<br />

machine components. Osterwalder AG in Lyss acquired the<br />

company 1974, transformed it into a stock corporation, and<br />

operated it as an independent subsidiary until 1992. Then<br />

Ingold Tools AG became an independent company again and<br />

currently has about 30 experienced and highly qualified<br />

employees. The range of services includes turning, milling,<br />

drilling, internal and external cylindrical grinding, surface<br />

grinding, honing lapping, assembly of components,<br />

sandblasting and polishing, as well as laser engraving. On stateof-the-art<br />

machines, such as fully automated multi-axis turning<br />

and milling centers, the company manufactures complex<br />

custom components from steel, non-ferrous and light metals<br />

and plastics. All components are produced with high precision,<br />

flexibility and short lead times, based on individual drawings<br />

and 3D data. The company is certified in accordance to ISO<br />

9001 and 14001. Components can be reconstructed from<br />

samples by creating 3D data for manufacturing them<br />

on request. Subcontractors handle heat treatments and<br />

surface coatings as partners.<br />

Ingold Tools, for example, produces standardized and customized<br />

jaws for a wide range of mechanically and hydraulically<br />

actuated chucks from numerous manufacturers. As an<br />

example of a particularly demanding machining process that<br />

he and his skilled staff executed easily, Christoph Jenzer<br />

presents a control piston coated with hard plastic. “To<br />

achieve a diameter and form accuracy of approximately 2 μm<br />

(0.000,080 ''), we first milled and drilled the pre-turned blank,<br />

had it coated with hard plastic at a partner company and subsequently<br />

ground the external and internal diameters on our<br />

tried-and-tested CNC grinding machines.”<br />

Expanding capacities<br />

To strengthen his good reputation in the industry and expand<br />

his precision machining capacities, Christoph Jenzer<br />

invested further in a CNC cylindrical grinding machine<br />

from STUDER. A tried-and-tested overhauled S41 universal<br />

cylindrical grinding machine with a swiveling wheelhead<br />

and four usable grinding spindle ends. “This machine<br />

enables us to reduce our lead times and increase our flexibility.<br />

On it we can grind components to completion in a single<br />

clamping operation,” explains Christoph Jenzer regarding<br />

his investment. He now considers it almost naturally that<br />

he can count on the support of the service technicians any<br />

time, just as he has done seven times in the past. “So far, our<br />

experience has been very good. Therefore we will continue<br />

to cooperate with STUDER. For a contract manufacturer who<br />

needs to operate productively and economically at all times<br />

and cannot tolerate machine downtime, the machines from<br />

STUDER have proven to be ideal,” adds Christoph Jenzer.<br />

Furthermore, the specialists at Ingold Tools are thoroughly<br />

familiar with the programming and operating interfaces of<br />

these CNC grinding machines. This is another advantage.<br />

The machine operators can effortlessly alternate between<br />

several machines. “Why would I bring in another manufacturer<br />

with an unfamiliar concept?” Christoph Jenzer<br />

asks rhetorically. Because of this he is already planning to<br />

purchase a ninth machine.<br />

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

no. 1, February <strong>2024</strong><br />


processes<br />

Complete solution for grinding and eroding<br />

The VHybrid 260 sharpening machine from<br />

VOLLMER offers a complete solution for grinding and<br />

eroding. Alexander Schmid explains why it is the epitome<br />

of flexibility and precision. Alexander Schmid is<br />

product manager for rotary and PCD tools and the<br />

person to contact at VOLLMER when it comes to the<br />

VHybrid combined grinding and erosion machine.<br />

Mr Schmid, the name says it all with the VHybrid 260<br />

grinding and erosion machine, but what exactly does<br />

“hybrid” mean?<br />

Alexander Schmid: the word “hybrid” is of Greek origin<br />

and describes something crossed or mixed. In term of<br />

technology, the VHybrid 260 combines the best of both<br />

worlds – “grinding” and “eroding”. Our erosion machines<br />

sharpen tools with PCD (polycrystalline diamond) using<br />

non-contact spark erosion. The concept of the VHybrid<br />

is based on that of our VGrind tool grinding machine,<br />

which enables multi-level machining using two vertically<br />

configured spindles. With the VHybrid the upper spindle<br />

is used purely as a grinding spindle, while the lower spindle<br />

can both erode and grind.<br />

What tool manufacturers are interested in a<br />

combined grinding and erosion machine?<br />

Alexander Schmid: all tool manufacturers who aim for<br />

a high degree of variability in tool manufacture. Our<br />

VHybrid is the ultimate in flexibility, allowing companies<br />

to adapt their tool manufacture to current demand any time.<br />

Regardless of whether carbide or diamond tools are required,<br />

the VHybrid offers a complete solution for both sharpening<br />

processes in a single machine. In addition the global market<br />

for tools shows that the use of complex tools such as fullhead<br />

PCD tools is steadily increasing. A combined machining<br />

process, consisting of erosion and grinding in a single<br />

set-up, is essential in order to produce these tools<br />

precisely and cost efficient.<br />

Isn’t a machine with two technologies more<br />

complicated to operate?<br />

Alexander Schmid: as far as the operation of the VHybrid<br />

is concerned, we at VOLLMER rely on our proven concept,<br />

which is based on intuitive operation with familiar software<br />

solutions. All machines customers can get are operated in<br />

the same way.<br />

You have incorporated simple operation and flexible use<br />

into the VHybrid; what technology is behind these<br />

advantages?<br />

Alexander Schmid: at the core of the VHybrid is our Vpulse<br />

EDM erosion generator, which we developed in our Research<br />

Alexander Schmid<br />

development. We are constantly working on making the<br />

generator more efficient. It currently achieves a surface<br />

quality of 0.05 μ Ra, which is equal to one thousand th of a<br />

hair’s breadth. Nevertheless we have customers who are<br />

less concerned with surface quality and want maximum<br />

machining speed instead. With the VPulse EDM erosion<br />

generator, a user can choose between maximum efficiency<br />

or the highest surface quality. With this option, a tool<br />

manufacturer can always adapt the sharpening process<br />

to its needs. What’s more, software-based V@ boost<br />

performance packages can improve the performance of<br />

the VHybrid by up to 35 %. Customers can activate the<br />

software package by the hour or purchase it permanently.<br />

Which industries or markets do you want to reach<br />

with the VHybrid 260?<br />

Alexander Schmid: From a market perspective, the global<br />

manufacturing industry worldwide now mainly requires<br />

PCD tools with less than 0 150 mm. Our VHybrid 260 is<br />

able to produce these types of tools, which then go on to<br />

be used throughout the woodworking and metalworking<br />

industries. At EMO 2023 we demonstrated for the first time<br />

how tool manufacturers can produce even the smallest<br />

microtools with 0 of 0.45 mm and below with the highest<br />

precision, performance and surface quality thanks to the<br />

optimized generator. PCD microtools with 0 of 0.45 mm<br />

and below are in particularly in demand for the production<br />

of microchips. Sectors such as the electronics industry or<br />

medical technology, which require ever smaller electronic<br />

components for increasingly compact implants and<br />

wearables, are benefiting from this in particular.<br />

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

36 no. 1, February <strong>2024</strong>

processes<br />

Automated cutting edge optimization of<br />

stamping and forming tools<br />

The challenge facing the OTEC team of experts was to find an<br />

automated solution that delivers consistently high-precision results<br />

for the stamping and forming machines of the renowned machine<br />

manufacturer Bihler. Optimum cutting edge rounding and a<br />

high-gloss polish on surfaces of the most varied tools made of hard<br />

metal or hardened steel are achieved in just one step using the OTEC<br />

machines. This ensures the long service life of tools and signifi cantly<br />

reduces production costs.<br />

Consistent high performance quality with measurable success<br />

For the tool industry, achieving the best possible product quality and increasing<br />

efficiency in the manufacture of stamping and bending parts are<br />

crucial for maintaining a competitive edge in the market. For the success<br />

story of Otto Bihler Maschinenfabrik, in particular, this means optimal cutting<br />

edge rounding of 10-20 μm and a high-gloss polish on the outer surfaces<br />

with a surface roughness of up to Ra 0.02 μm for cutting punches and dies.<br />

This high performance quality means that even with a higher cycle time,<br />

the hard metal or hardened steel tools achieve consistently and reliably precise<br />

results and a maximum service life. Using the latest 3D measuring technology<br />

from Keyence the quality is also constantly and reliably checked and<br />

documented.<br />

Precise process flexibility using an<br />

automated Stream Finishing solution<br />

A customized process designed to fully meet the exacting surface requirements<br />

was developed in the OTEC Finishing Center. The requested roughness<br />

parameters for the stamping and forming tools were achieved by using<br />

mass finishing technology, what is called the Stream Finishing process.<br />

With the SF technology workpieces are clamped in a holder and lowered<br />

into a rotating container filled with an abrasive or polishing medium. The<br />

granulate-type abrasive circulates around the workpieces, thereby ensuring<br />

even, homogeneous abrasion. By adjusting the processing parameters and<br />

the type of abrasive used, both highly abrasive and fine polishing processes<br />

can be performed with just one machine.<br />

A special cycle mode in the machine means that this process is also suitable<br />

for the most varied tool geometries. The angle of the clamped tool is repeatedly<br />

changed automatically during the process so that the most varied<br />

surfaces can be specifically targeted. Thanks to the optimized processing of<br />

the tools in the Stream Finishing unit, manual process steps (tasks) are no<br />

longer required. The innovative solution is reliable and delivers consistent<br />

results without fluctuations.<br />

Hand-in-hand: implementation of the process for the customer<br />

The successful interaction between machine size and equipment, abrasive<br />

and the correct process parameters was determined as a process using tools<br />

used in series production by the customer and then tested in real use. Following<br />

installation of the OTEC SF-1 with intermittent drive, the unit was<br />

successfully commissioned at Bihler with the help of the OTEC specialists.<br />

Continued support from Process Development and After-Sales will guarantee<br />

excellent process reliability and efficient use of the unit on a long-term<br />

basis.<br />

Benefits of OTEC surface processing<br />

• surface roughness parameters<br />

are significantly reduced<br />

• flexible processes for the most<br />

varied requirements for tools<br />

• fast processing<br />

• no fluctuations in quality as a<br />

result of automation<br />

• durable high-quality products and<br />

increased productivity hines<br />

The surface is now the top performer<br />

The use of the OTEC Stream Finishing units<br />

leads to effective resource and cost savings<br />

while at the same time achieving the required<br />

surface roughness parameters and surface<br />

properties. The extremely high demands of<br />

hard metal tools in terms of consistently high<br />

product quality and increased effectiveness<br />

in production are reliably met and the service<br />

life of the parts is increased significantly<br />

while at the same time reducing maintenance<br />

costs.<br />

The special property of the mass finished<br />

surface topography with its significant reduction<br />

in roughness peaks allows excellent performance<br />

of the tools. Smoothing and polishing<br />

of the surfaces reduces friction and thus<br />

the thermal load. This significantly reduces<br />

wear on the tools and prepares the surface<br />

perfectly for a coating.<br />

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

no. 1, February <strong>2024</strong><br />


machining center<br />

Swiss quality as a price leader<br />

STUDER is internationally renowned for its high-end cylindrical<br />

grinding machines, but even with its entry-level machines, cus tomers<br />

benefit from uncompromising quality and precision.<br />

“We are continuously expanding our entry-level range for customers who<br />

appreciate STUDER quality and utmost precision but do not need all<br />

the features from the premium segment,” says Sandro Bottazzo, CSO of<br />

Fritz Studer AG. He describes the philosophy behind the entry-level<br />

machines in the product range as “uncompromising STUDER quality and<br />

precision at an entry-level price.” Specifically the machines in the entry-level<br />

segment include the favorit, favoritCNC and S100 models.<br />

But what exactly is an entry-level machine? “Compared to our high-end<br />

models, the number of tools and range of spindle power is limited, and many<br />

technical processes and interfaces standardized – this allows them to cover<br />

a wide range of grinding applications with excellent value for money,” says<br />

Daniel Huber, CTO of STUDER. Depending on the model, optional accessories<br />

and adaptations are also possible, allowing companies to make their<br />

specific production even more efficient. STUDER thus has the right machine<br />

for every area of application. “Our sales staff and representatives are familiar<br />

with the specifications of each machine and can accordingly offer the suitable<br />

model with the optimal configuration”, adds Bottazzo.<br />

The best of both worlds<br />

Customers get the best of both worlds: they benefit from an economical price<br />

while receiving an uncompromisingly high-quality product with the globally<br />

recognized STUDER performance, utmost reliability and maximum precision.<br />

Another unique feature that all STUDER entry-level machines have<br />

in common is very short delivery times. This is possible thanks to the company’s<br />

in-house manufacturing concept and flow assembly+ (plus). Here<br />

STUDER’s experts assemble the machines on a specially designed, highprecision<br />

conveyor system. Customers benefit from the shortest throughput<br />

times and high manufacturing quality.<br />

Okyay Erik, general manager of the Turkish automotive supplier Celikis,<br />

describes what this means for customers in practice: “We were surprised by<br />

what the STUDER favorit can achieve, even though it’s classified as an entrylevel<br />

machine.” The company based in Izmir<br />

produces various products including differential<br />

gears, shafts and housings for major<br />

automobile manufacturers. “With the favorit<br />

we have significantly increased the efficiency<br />

of our driveshaft production,” reports Erik.<br />

“Where we used to produce 15 drive shafts per<br />

hour, we now manage 25 in the same amount<br />

of time. Plus, we no longer need to use a measuring<br />

system, as the machine’s accuracy is<br />

very high. This in turn reduces reset times,<br />

significantly boosting productivity.”<br />

Entry-level machines can handle<br />

key applications<br />

As a CNC universal cylindrical grinding machine<br />

that is easy to program thanks to the 24"<br />

multitouch screen, the favorit can grind both<br />

short and long workpieces weighing up to<br />

150 kg (330 lbs) – in single or series production.<br />

The cross and longitudinal slides, made of<br />

high-quality gray cast iron, ensure the highest<br />

precision. As all STUDER machines, the machine<br />

bed is made of the patented mineral<br />

casting Granitan®, which ensures the best surface<br />

quality of the ground parts with its excellent<br />

damping and thermal behavior. These are<br />

just a few examples of how customers benefit<br />

from STUDER’s premium manufacturer<br />

status even in entry-level machines.<br />

The same applies to the favoritCNC. This<br />

CNC universal cylindrical grinding machine<br />

is the leader in terms of value for money and<br />

can be adapted to a variety of grinding tasks<br />

with different options such as a measuring<br />

system, balancing system, contact detection,<br />

and longitudinal positioning. With a distance<br />

between centers of 650 mm (25.6") or<br />

1000 mm (39.4"), it is universal usable and can<br />

handle key applications. Its high grinding precision,<br />

even at this entry-class level, is demonstrated<br />

by its high roundness accuracy of less<br />

than 0.0004 mm (0.000,016"). And thanks to<br />

the in-house StuderPictogramming grinding<br />

software even complex grinding cycles can<br />

be executed easily and intuitively.<br />

The CNC universal<br />

internal cylindrical grinding machine S100<br />

Ease of use is particularly important<br />

With the S100 there is also a specialist for<br />

internal cylindrical grinding in the entrylevel<br />

portfolio, serving as the counterpart to<br />

the favoritCNC in external cylindrical grinding.<br />

It handles a wide range of internal, face,<br />

38 no. 1, February <strong>2024</strong>

machining center<br />

The CNC<br />

universal cylindrical grinding machine favoritCNC<br />

and external grinding applications with the highest accuracy and is thus<br />

the ideal universal internal cylindrical grinding machine in this segment.<br />

Its specialty is the complete machining of workpieces with a length of up<br />

to 550 mm (21.65 ") (including clamping devices) and a 0 of up to 420 mm<br />

(16.5 "). Thanks to the wheelhead with multiple grinding spindles and<br />

QuickSet for quick setup, it significantly reduces setup and resetting costs.<br />

The S100 is also easy and quick to control, with ergonomically arranged<br />

operating elements and StuderPictogramming. “Ease of use is also particularly<br />

important for entry-level machines”, says CSO Bottazzo.<br />

In numerous locations, shrinking and aging populations are making it<br />

increasingly difficult to replace retiring workforces who, through their years<br />

of experience, could achieve high quality with manual grinding machines.<br />

“Thanks to the innovative technology, intuitive software, and simple operation<br />

of our entry-level machines, our customers’ employees can grind workpieces<br />

of the highest quality after just a few days of training,” explains CTO<br />

Huber.<br />

Automation is also becoming increasingly important. It helps to save time<br />

and work for operators and makes overall production more efficient. For instance<br />

the favorit and the S100 can be equipped with a standardized loader<br />

interface, which can automatically open and close the operating door. “Customers<br />

can thus integrate the machine into their automated production<br />

processes, for example, with a robotic arm or a gantry loader,” says Huber.<br />

Wide range of applications<br />

As a globally established grinding machine manufacturer with over 111 years<br />

of tradition, STUDER is also well-acquainted with the varying regional<br />

requirements in the entry-level sector. “Besides high quality and precision,<br />

top reliability is particularly important. Our customers, particularly small<br />

and medium-sized enterprises, appreciate that they can grind highly economically<br />

with our machines, practically without any downtime”, says<br />

Bottazzo. Technical standardization not only ensures an economical price<br />

but also a low susceptibility to errors. Should a problem occur, STUDER’s<br />

customer-oriented and efficient Customer Care is quickly available to provide<br />

expert assistance.<br />

But what is the typical clientele for an entry-level machine? There isn’t one,<br />

thanks to the wide range of applications these machines cover. Whether it’s<br />

an automotive supplier at the highest international level like Celikis in Turkey<br />

or manufacturers of woodworking tools, hydraulic parts for the aviation industry,<br />

shafts for tractors, or tungsten carbide components for drawing dies:<br />

all this and much more can be achieved with STUDER’s entry-level machines<br />

– economically, efficiently and without compromising on quality.<br />

advantages of STUDER’s<br />

entry-level machines:<br />

➤ products with the highest STUDER quality<br />

and precision<br />

➤ attractive value for money with<br />

short delivery times<br />

➤ standardized grinding machines with<br />

various configurations<br />

➤ easier operation and simple maintenance<br />

for operators<br />

➤ machining of workpieces in<br />

different sections<br />

➤ grinding of threads or non-round shapes<br />

possible<br />

➤ optional integration of a loader interface<br />

and an automatic operator door,<br />

depending on the model<br />

favorit<br />

➤ CNC universal cylindrical grinding<br />

machine for the individual and<br />

batch production of short to<br />

long-sized workpieces<br />

➤ distances between centers of<br />

400/650/1000/1600 mm<br />

(15.7’’/25.6’’/39.4’’/63’’) and a<br />

center height of 175 mm (6.9”)<br />

➤ workpieces with a maximum weight of<br />

150 kg (330 lbs)<br />

➤ external and internal grinding possible<br />

in one setup<br />

favoritCNC<br />

➤ the CNC universal cylindrical grinding<br />

machine is a leader in value for money<br />

and suitable for universal use<br />

➤ distances between centers of 650 mm<br />

(25.6”) or 1000 mm (39.4“) and a<br />

center height of 175 mm (6.9”)<br />

➤ workpieces with a maximum weight of<br />

80 or 120 kg (176 or 264 lbs)<br />

➤ external and internal grinding possible in<br />

one setup<br />

S100<br />

➤ the ideal CNC universal internal cylindrical<br />

grinding machine for the entry-level<br />

segment covers a wide range of internal,<br />

face and external grinding applications<br />

➤ workpiece length (incl. clamping device) of<br />

550 mm (21.65”) and maximum workpiece<br />

0 of 420 mm (16.5”)<br />

➤ grinding 0 external:<br />

max. 420 mm (16.5”) /<br />

internal: max. 300 mm (11.8”) /<br />

grinding length internal:<br />

max. 200 mm (7.87”)<br />

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

no. 1, February <strong>2024</strong><br />


machining center<br />

Designed for production<br />

A benchmark in cutting performance and precision<br />

With the presentation of the F 6000 5-axis machining<br />

center, HELLER has launched a new generation<br />

of the F series. The benefits: increased cutting performance<br />

and higher precision, maximum reliability for<br />

24/7 production, optimum ease of operation and a<br />

compact machine footprint.<br />

Dr. Eng. Manuel Gerst, head of development of the HELLER<br />

Group, adds: “With the F 6000 we have succeeded in raising<br />

the already high standard to a new level, also due to newly<br />

developed key components ‘Made by HELLER’ such as spindles,<br />

heads and tables whilst consistent standardization also<br />

helps us to ensure full compatibility with previous models.”<br />

Following intensive development work, HELLER’s new<br />

F 6000 5-axis machining center is available for order since<br />

September 2023. It can be used for all areas of 5-axis machining,<br />

including optional combined mill/turn operations,<br />

from heavy-duty cutting through to machining of<br />

light metals. The machine is just as efficient for the manufacture<br />

of single parts as it is for series production. As a<br />

result the F 6000 offers a compelling solution for companies<br />

in a wide range of industries – from general mechanical<br />

engineering, power train and power engineering through to<br />

aerospace.<br />

Dr. eng. Manuel Gerst,<br />

head of development<br />

of the HELLER Group:<br />

“With our new, powerful<br />

and compact F 6000<br />

5-axis machining center,<br />

we offer users even<br />

greater productivity<br />

and flexibility”<br />

With its modular design the F 6000 combines and extends<br />

the capabilities of the previous F series and the mill/turn machining<br />

centers from the C series. Topology-optimized structural<br />

components and the improved machine design guarantee<br />

high basic stability. With a wide range of options available,<br />

the machine can be optimally tailored to the needs of<br />

each individual customer, ensuring maximum productivity<br />

in practical use.<br />

Spindle units with in-house<br />

developed motor spindles<br />

The HELLER team, led by head of development Manuel Gerst,<br />

has made numerous improvements. Highlights of the new<br />

generation include the completely redesigned swivel heads<br />

with integrated motor spindles specially developed by the<br />

company. The Speed Cutting Unit (SCU) in combination<br />

with the HSK-A 100 tool shank reaches speeds of 15,000 rpm.<br />

As an alternative, the company offers the Dynamic<br />

User-friendliness is paramount with the new F 6000;<br />

the standard SINUMERIK ONE control contributes to this,<br />

as does the significantly wider door to the work area<br />

The completely redesigned swivel heads with integrated<br />

motor spindles, specially developed by HELLER, contribute<br />

significantly to the high accuracy and dynamics of the F 6000<br />

40 no. 1, February <strong>2024</strong>

machining center<br />

HELLER’s new F 6000 was unveiled at EMO 2023<br />

and is available for order since then<br />

The optional DDT (Direct Drive Turning)<br />

rotary table can reach speeds of up to 700 rpm;<br />

this allows simultaneous 5-axis machining<br />

and turning operations to be performed<br />

in a single set-up<br />

Cutting Unit (DCU) designed for universal<br />

use with 380 Nm and 12,000 rpm. For heavyduty<br />

machining, the Power Cutting Unit<br />

(PCU) with a gear spindle and 1,150 Nm is<br />

still available.<br />

Equally elementary is the revised drive concept<br />

of the linear axes, with two ball screws<br />

in the Z-axis and the significantly reinforced<br />

X-axis. “The machine offers much higher<br />

dynamics in the linear axes. At the same<br />

time the positioning tolerances have been<br />

greatly reduced for the PRO package. The<br />

new standard is 5 µm, with 4 µm available as<br />

an option. Tolerances on the rotary B- and<br />

C-axes have also been reduced and are now<br />

7 arc seconds as standard. Overall, this is<br />

reflected in the workpiece, reaching new top<br />

marks for accuracy and machining time”,<br />

explains Gerst.<br />

High-speed rotary table<br />

for complete machining<br />

The F 6000’s Mill-Turn option ensures greater<br />

precision and shorter production times for<br />

workpieces that also require turning in addition<br />

to complex milling operations. This is ensured<br />

by the high-speed DDT (Direct Drive<br />

Turning) rotary table available for the new<br />

machining center. It offers high torque and<br />

can reach speeds of up to 700 rpm. This means<br />

that, in addition to conventional milling<br />

and drilling operations, external and internal<br />

contours can be machined in a single setup<br />

using the turning functionality. The wide<br />

range of machining cycles covers virtually<br />

all the capabilities of a conventional turning<br />

machine.<br />

New hardware and software ensure<br />

greatest possible ease of operation<br />

Another major strength of the F 6000, according to Manuel Gerst, is the ease<br />

of use it offers in every respect. The comfortable main operating unit in console<br />

design with 24-inch touch screen and other features ensures that the<br />

operator quickly gets to grips with the machine. In addition, the signifi -<br />

cantly wider door to the work area provides easier access to the workpiece.<br />

Bright work area lighting, an additional LED light in the swivel head and an<br />

optional work area camera ensure good visibility when setting up new workpieces.<br />

The optional SETUP Assist allows new processes to be set up quickly<br />

and safely on the machine.<br />

The new Siemens SINUMERIK ONE control is available as standard.<br />

Existing NC programs from F- and C-series machines equipped with<br />

SINUMERIK 840D sl can be transferred directly and easily by the user.<br />

Manual Gerst: “Compatibility with our previous machines is very important<br />

to us. This means that tools, machine pallets and fixtures from our 4-axis<br />

and 5-axis series are compatible and can continue to be used on the F 6000.”<br />

Automation for every requirement – even as a retrofit solution<br />

The pallet changer, as the first level of automation, provides a reliable basis<br />

for automated series production of small, medium or large batches. The<br />

F 6000 is equipped with a pallet changer as standard and can easily be extended<br />

with a standardized linear or rotary storage. The new ‘Automationready’<br />

option allows the HELLER rotary pallet storage (RSP) and HELLER’s<br />

standardized linear storage solutions to be retrofitted easily, cost-effectively<br />

and quickly – without having to modify the machine.<br />

Free chip fall below the spindle increases process reliability. To this end,<br />

the designers have incorporated a wide chip conveyor, steep covers in the<br />

work area and stainless steel cladding of the chip chutes to ensure effective<br />

chip evacuation. The new machine design, and in particular the direct chip<br />

disposal to the rear of the machine, has resulted in a significantly smaller<br />

footprint of the F 6000. The machine’s narrow width of 3.70 m is an advantage,<br />

especially when automating multiple machining centers and allows for<br />

a much better use of the available space.<br />

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

no. 1, February <strong>2024</strong><br />


machining center<br />

Nothing is impossible<br />

Optimized chamfering of internal gears<br />

during the machining process<br />

On the new LK 280 DC gear skiving machine from<br />

Liebherr-Verzahntechnik GmbH, internal gears can not<br />

only be produced efficiently, but also chamfered during<br />

the machining process thanks to an integrated<br />

ChamferCut device. This opens new opportunities for<br />

manufacturing gearboxes with higher power density,<br />

giving them a competitive edge in the market for modernized<br />

or alternative drive technologies.<br />

New drive designs require gearboxes with greater power<br />

densities, and not just for the electromobility sector. Planetary<br />

gears are therefore being used more and more frequently,<br />

which deliver a higher transmission ratio at a smaller volume.<br />

However, the possibilities for chamfering the internal<br />

gears required for this have been limited up to now. “There<br />

was a desire in the industry for economical and high-quality<br />

chamfering solutions for internal gears. But up to now these<br />

seemed almost impossible to put into practical use,” says<br />

Dr. Oliver Winkel, head of application technology at Liebherr-<br />

Verzahntechnik GmbH, describing the situation at the get-go.<br />

Now the company is first in presenting a machine which<br />

does exactly that: by making use of an exciting new cutting<br />

method to make a defined, exact chamfer on an internal<br />

gear – and to do just that during the machining process and<br />

with high precision to boot. In this way previously formed<br />

burrs are removed and, at the same time, the leading edges<br />

are broken, which creates the best conditions for assembly,<br />

application behavior or any subsequent hard gear finishing.<br />

Modular machine design with pick-up spindle<br />

This is made possible by Liebherr’s modular machine design,<br />

which allows the ChamferCut device to be integrated into<br />

the machine. The chamfering device is at a right angle to the<br />

main machining and is fed by a ringloader. For the particular<br />

requirements of chamfering internal gears, Liebherr has<br />

developed a new type of pick-up spindle that lifts the workpiece<br />

and thus makes the burred underside of the internal<br />

gears accessible for the ChamferCut tool. “That’s where our<br />

strength lies; in developing innovative solutions and new machine<br />

designs for new component requirements. The knowhow<br />

was there, and the first customer inquiry got the ball<br />

rolling. We were offered the opportunity to make a machine<br />

just for this purpose,” explains Winkel. The gear skiving<br />

machine with integrated chamfering device is already in use<br />

at a well-known gear manufacturer.<br />

Tried and true ChamferCut tools from LMT FETTE<br />

“The tool manufacturer LMT FETTE, which exclusively supplies<br />

us with ChamferCut tools, had the tools for chamfering<br />

internal gears (ChamferCut IG: Internal Gear) in its product<br />

range. We then developed and built the machine for this,<br />

so to speak,” Winkel continues. “The customer approached<br />

us because they had good experience with our gear skiving<br />

tools in the past and trusted us to provide the solution for the<br />

new requirements.” Another new feature of the machine was<br />

that it also allows clean and environmentally friendly dry<br />

machining during gear skiving and chamfering. With this,<br />

Liebherr offers a machine for economical and series production<br />

of internal gears with a defined chamfer.<br />

Versatile: one machine, two technologies<br />

But the machine is also suitable for changing between large<br />

and small batch sizes with a higher part variance. The<br />

changeover to the FlexChamfer process, in which the chamfer<br />

is generated by CNC-control with standard shank cutters,<br />

is easily realized with a simple switchover of the control<br />

system and opens up the greatest possible versatility in the<br />

application. “You only have to retool the machining head and<br />

switch between software programs. So you practically get one<br />

machine with two technologies and can produce large series,<br />

but also prototypes and small series economically and efficiently,”<br />

states Martin Schwarzmann, product manager for<br />

gear technology.<br />

ChamferCut IG as a stand-alone solution<br />

ChamferCut technology for chamfering internal gears can<br />

also be integrated into existing production processes as a<br />

stand-alone solution. The chamfer machines in the LD series<br />

are designed for either dry or wet machining and can be<br />

combined with various automation options. Winkel sums up,<br />

“With our machine design, we have succeeded in developing<br />

an innovative solution for the component requirements of<br />

current and future planetary gears.”<br />

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

42 no. 1, February <strong>2024</strong>

machining center<br />

New peripheral and double T-land grinding machine<br />

for the European market<br />

After taking over the RETROFIT responsibility<br />

for top and bottom, grooving<br />

insert/plunge-cut and profile grinding<br />

machines of WENDT GmbH (3M<br />

Group) in 2017, HDC Huttelmaier GmbH<br />

is adding a new machine to its machine<br />

portfolio for this year’s GrindingHub.<br />

This is the CPG400 peripheral and double<br />

T-land grinding machine for the<br />

European market, and it completes<br />

HDC’s program for the main grinding<br />

applications on inserts from the blank to<br />

the finished product.<br />

Grinding machine<br />

CPG400<br />

HDC thus offers an alternative with an excellent<br />

price-performance ratio in this previously<br />

one-sidedly dominated market. The European<br />

market launch will take place with the presentation<br />

at GrindingHub (May 14.-17., <strong>2024</strong>) in<br />

Stuttgart, on the HDC-booth in hall 9.<br />

The facts<br />

The automated, 4-axes peripheral and doublesided<br />

T-land grinding machine CPG400 is<br />

perfect especially for ultra-hard materials<br />

such as PCD, PCBN, ceramics, cermets, etc.<br />

The basic machine which has been in use in<br />

Asia x-100 times for years and is constantly<br />

being developed further, is built by LMT in<br />

China. The high reliability and repeat accur-<br />

Robot load<br />

acy of the CPG400 is largely the result of established German and Japanese<br />

brand components. The latest updated version of the CPG400 is now also<br />

available from HDC Huttelmaier for the domestic market.<br />

In addition to implementing European standards, HDC, as an experienced<br />

specialist for grinding machines, is responsible for CE certification and technical<br />

implementation. HDC also offers the adaptation of the machine to<br />

individual demands and acts as contract and service partner. After the<br />

GrindingHub, the CPG400 will also be available for grinding tests in the<br />

HDC showroom in Schorndorf (near Stuttgart).<br />

Workroom dressing wheels<br />

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

no. 1, February <strong>2024</strong><br />


components<br />

Innovative cutting oils for<br />

non-ferrous metal processing<br />

Lubricant manufacturer Zeller+Gmelin is launching<br />

four new high-performance cutting oils for nonferrous<br />

metal processing: Multicut Grind HP 15 NF for<br />

cylindrical or profile grinding, Multicut FSE<br />

HSC 15 NF for demanding high-speed machining, Multicut<br />

Basic HP 15 Extra NF as a universal product for steel and<br />

non-ferrous metals, as well as Multicut Plus 10 NF as an allround<br />

cutting oil for conventional, medium-duty machining<br />

tasks. Thanks to their special formulation they easily cope<br />

with the special requirements when machining non-ferrous<br />

metals and at the same time deliver first-class results in terms<br />

of tool life and performance.<br />

Sulphur additives are actually known to increase the performance<br />

of non water-miscible cooling lubricants. However<br />

the resulting metal sulfide layer, which normally reduces wear<br />

during machining and improves lubrication, proves to be extremely<br />

counterproductive when it comes to non-ferrous<br />

metals. Copper and copper-containing compounds such as<br />

bronze or brass in particular react sensitively to sulphur compounds.<br />

The consequences are increased corrosion, black<br />

spots, discolored components and inferior part quality. And<br />

this in turn leads to disruptions in the production process,<br />

longer downtimes and waste of raw materials.<br />

Sustainable and resource-saving cutting oils<br />

With the special NF products from the Multicut portfolio,<br />

Zeller+Gmelin has specialized in lubricants that meet<br />

the technical challenges in non-ferrous metal processing.<br />

According to the manufacturer they are ideal for metal processing<br />

from turning, milling and drilling to thread processing<br />

and deep hole drilling. At the same time the experts are<br />

constantly working to increase the efficiency, quality and sustainability<br />

of their cutting oils. And they are also looking for<br />

new, sustainable formulations – relying increasingly on contemporary<br />

base oils such as hydrocracking oils and resourcesaving<br />

esters.<br />

Machining economically<br />

“With Multicut we fully meet the increased requirements of<br />

a modern industry, because our cutting oils deliver excellent<br />

results even with demanding materials and in delicate machining<br />

processes,” emphasizes Dr. Irene Kreitmeir, product<br />

manager for lubricants at Zeller+Gmelin. Many of the extended<br />

formulations of the Multicut NF products are not only<br />

suitable for the most demanding machining tasks and difficult-to-machine<br />

materials, but also specifically for the<br />

machining of sensitive non-ferrous metal alloys, such as<br />

beryllium copper, which is so often used in the watch industry.<br />

“A decisive factor of our Multicut NF cutting oils is the<br />

reduced consumption,” explains Dr. Irene Kreitmeir. “Due to<br />

Used in particular by watch manufacturers:<br />

the new high-performance cutting oil<br />

Multicut FSE HSC 15 NF from Zeller+Gmelin<br />

is compatible with non-ferrous metals and<br />

is suitable, for example, for beryllium copper<br />

(source Pixabay)<br />

the low oil mist formation and the low evaporation loss, oil<br />

consumption is reduced immensely, which means that companies<br />

can save costs in the long term.” Additionally there is<br />

the low foam formation and the good air separation capacity,<br />

which ensures uniform lubricating properties and thus<br />

leads to improved machining qualities and longer tool life.<br />

The high flash points of the Multicut NF cutting oils also<br />

ensure increased safety during handling and reduce the risk<br />

of fires or injuries.<br />

A range for all requirements<br />

The Multicut NF cutting oils are particularly suitable for sensitive<br />

non-ferrous metal alloys, but also for soft free-cutting<br />

steels, case-hardened and tempered steels and sometimes<br />

even for high-strength, acid- and rust-resistant steels.<br />

The high-performance grinding oil, Multicut Grind HP 15<br />

NF is ideal for various machining processes such as cylindrical<br />

or profile grinding. It offers a high pressure absorption capacity,<br />

good wear protection and guarantees excellent surface<br />

quality. It is not only suitable for grinding non-ferrous<br />

metals, but can also be used in machines that process nonferrous<br />

metals. In addition an approval from the grinding<br />

machine manufacturer Junker in Nordrach is available.<br />

further information: www.zeller-gmelin.de<br />

44 no. 1, February <strong>2024</strong>

Support-free 3D printing opens up new<br />

applications and reduces waste<br />

components<br />

High-tech company TRUMPF recently<br />

made improvements to its 3D printing<br />

software TruTops Print. Users can now<br />

print parts with extreme overhang angles<br />

as low as 15 ° without requiring support<br />

structures. TRUMPF showcased its<br />

new technology at EMO.<br />

“The latest version of TRUMPF’s TruTops<br />

Print software eliminates the need for virtually<br />

all support materials, which ultimately<br />

means quicker builds and lower material<br />

consumption,” says Lukas Gebhard, process<br />

development engineer for additive manufacturing<br />

at toolcraft. “Support-free printing<br />

gets parts close to their final shape. It opens<br />

the door to parts and projects that were previously<br />

impossible, such as the near-netshape<br />

manufacturing of large-diameter internal<br />

cooling channels.” In the past users had<br />

to print support structures together with the<br />

part in order to anchor the part to the build<br />

platform. These structures also serve to dissipate<br />

heat from the printed part and prevent<br />

internal tensions and deformations during<br />

printing. But this innovative new technology<br />

means that many 3D printing applications<br />

can now be carried out without supports,<br />

even when tackling hard-to-process materials<br />

such as stainless steel.<br />

Software opens up new 3D<br />

printing strategies<br />

“When we 3D print a part, we want as much<br />

control as possible over when and where the<br />

material melts and re-solidifies. The skill lies<br />

in choosing the right exposure strategies to<br />

prevent internal tensions and overheating in<br />

the overhang region,” says Timo Degen, product<br />

manager for additive manufacturing.<br />

TruTops Print enables the 3D printer to use<br />

the optimum printing strategy for every different<br />

area of the part, thus eliminating the<br />

need for support structures. At the same time<br />

the improved gas flow of the new 3D printers<br />

caters to uniform processing conditions and<br />

support-free printing.<br />

Support-free 3D printing<br />

opens up new applications<br />

“Users from any industry can benefit from<br />

the ability to 3D print parts without supports.<br />

TruTops print allows users to print parts with extreme overhangs<br />

as low as 15 ° without requiring support structures<br />

The advantages of support-free printing are particularly appealing<br />

for parts that feature large cavities or challenging overhangs<br />

The advantages of support-free printing are particularly appealing for parts<br />

that feature large cavities or challenging overhangs,” says Degen. Examples<br />

include tanks, heat exchangers, hydraulic blocks and tool molds.<br />

The new technology also opens up new applications that couldn’t be properly<br />

exploited when support structures were still necessary, including areas<br />

such as additively manufactured radial compressors and shrouded impellers.<br />

Previously manufacturers were unable to print support-free impellers due to<br />

their overhang angles. “The need for supports meant that 3D printing wasn’t<br />

an economically viable alternative to conventional manufacturing. But now<br />

things are different,” says Degen.<br />

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

no. 1, February <strong>2024</strong><br />


components<br />

New precision clamping fixture simplifies<br />

turning and milling processes<br />

More flexibility in machining production<br />

and significantly reduced setup<br />

times – these are the premises under<br />

which RINGSPANN presents the new<br />

HSFS 110 clamping sleeve chuck. This innovative<br />

precision clamping system offers<br />

numerous advantages, especially for<br />

users of turning/milling machines with<br />

main and counter spindles and machine<br />

tools with bar loaders.<br />

Since it does not require pull-back action, it is<br />

equally suitable for machining bar stock and<br />

material sections in the first or workpieces<br />

from the second clamping step.<br />

“The aspects of increasing flexibility and reducing<br />

setup times were the focus of our considerations<br />

for a new clamping system for use<br />

in machining production”, says Christoph<br />

Schulz, product manager clamping fixtures<br />

at RINGSPANN. As a concrete result of<br />

the development work the company is now<br />

presenting the HSFS 110 clamping sleeve<br />

chuck, which is of interests both machine<br />

builders and users. The new precision clamping<br />

system from the company offers considerable<br />

efficiency advantages, especially when<br />

using machine tools with fully automatic<br />

barfeeders and turning-milling machines<br />

with two spindles. Including is the fact that it<br />

works without pull-back action – a technical<br />

prerequisite for use with bar loaders – and that<br />

its design allows for a very simple and quick<br />

replacement of the clamping sleeves.<br />

With clamping diameter range from 22 mm<br />

to 80 mm, the new HSFS 110 from the company<br />

is an extremely versatile clamping fixture<br />

for many different tasks. It also provides<br />

the user with additional flexibility, not least<br />

because it allows the clamping diameter to<br />

be changed by up to 1.5 mm. “Our HSFS 110<br />

allows for large workpiece tolerances and insertion<br />

clearances. It is therefore also suitable<br />

for automated loading”, explains Christoph<br />

Schulz.<br />

Christoph Schulz, product manager Clamping<br />

Fixtures at RINGSPANN: “Since our new<br />

HSFS 110 clamping sleeve chuck allows<br />

for large workpiece tolerances and<br />

insertion clearances, it is also<br />

suitable for automated<br />

loading.”<br />

draw tube<br />

adapter<br />

adapter flange for<br />

spindle heads<br />

basis chuck<br />

backstop plat<br />

(optional)<br />

clamping<br />

sleeve<br />

The new HSFS 110 clamping sleeve chuck from RINGSPANN is a<br />

purely mechanical clamping system and consists of a base chuck, a<br />

clamping sleeve as well as a draw tube adapter and an adapter flange<br />

Clamping principle of the new HSFS 110: preloaded clamping discs<br />

are located in an axially movable holder; during clamping, the holder<br />

is shifted axially, the clamping discs straighten up and the clamping sleeve<br />

rests against the workpiece; in this process, the workpiece is centred,<br />

and the axial actuating force is translated into a radial clamping force<br />

that is up to ten times greater<br />

46 no. 1, February <strong>2024</strong>

components<br />

The new HSFS 110 clamping sleeve chuck offers<br />

more flexibility in machining production and<br />

enables significantly reduced setup times<br />

The new HSFS 110 offers efficiency advantages,<br />

especially in tool making with fully automatic bar loaders<br />

and turning-milling machines with two spindles; it works<br />

without pull-back action and allows for easy,<br />

quick replacement of the clamping sleeves<br />

Clamping sleeve as an interchangeable part<br />

The new HSFS 110 clamping sleeve chuck is a purely mechanical<br />

clamping system and consists of a base chuck, a clamping<br />

sleeve as well as a draw tube adapter and an adapter<br />

flange. While the adapter flange connects the machine spindle<br />

to the base chuck, the draw tube adapter transfers the actuating<br />

force from the clamping force device of the machine<br />

spindle into the base chuck. The clamping sleeve is an interchangeable<br />

part that can be replaced easily, quickly and as required<br />

without special tools. "In addition, the use of individually<br />

designed stop plates makes it possible to load and process<br />

workpieces axially positioned from the front. That is why<br />

the HSFS 110 is also usable for material sections in the first<br />

clamping step without any problems,” says Christoph Schulz.<br />

The clamping principle of the new HSFS 110 can be described<br />

in a few words: clamping discs with preload are<br />

located in an axially movable mount. If the holder is then<br />

shifted axially during clamping, the clamping discs straighten<br />

up and the clamping sleeve firmly clamps the workpiece. In<br />

this process the workpiece is centered, and the axial actuating<br />

force is translated into a radial clamping force up to ten<br />

times greater. The maximum torque achievable depends on<br />

the diameter of the bar material to be machined. Two limits<br />

provide orientation: rods with 0 of 80 mm are clamped at<br />

up to 470 Nm, while the maximum torque for rods with 0 of<br />

22 mm is 85 Nm. “At the same time the chuck of the HSFS 110<br />

ensures uniform, safe and precise 360 ° clamping around the<br />

workpiece at all times,” emphasizes Christoph Schulz. In<br />

numerous tests the HSFS was able to attest to an extremely<br />

smooth running.<br />

Sleeves, flanges and plates for all occasions<br />

The specific size of the HSFS 110 clamping sleeve is defined<br />

by the rod’s diameters or the sections and workpieces that<br />

are to be machined. As standard the company offers a selection<br />

of 28 different clamping sleeves for as many diameters of<br />

rods (according to EN 10278) or cylindrical workpieces. The<br />

clamping sleeve can be changed in just a few simple steps, no<br />

special tools are required – an Allen key is sufficient!<br />

The adapter flanges for connection to the spindle heads of<br />

various machine tools are always designed by RINGSPANN<br />

according to customer requirements. According to Christoph<br />

Schulz, “short flanges for short-cone connections are also<br />

part of the range”.<br />

The draw tube adapters are also adapted to the specific case –<br />

here the spindle geometry and the design of the draw tube of<br />

the power clamping device serve as decisive specifications. As<br />

indicated before, the stop plates can be individually designed<br />

for front loading with material sections or workpieces.<br />

With the new HSFS 110 clamping sleeve chuck manufacturers<br />

and users of machine tools are being offered a modern<br />

precision clamping system, on which many turning and<br />

milling processes of the first and second clamping step can<br />

be carried out extremely flexibly and efficiently. Thanks to<br />

its high adaptability and easy handling it is also one of those<br />

clamping systems that can give the machining of workpieces<br />

a noticeable economic efficiency impulse.<br />

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

no. 1, February <strong>2024</strong><br />


components<br />

High-performance coolant filtration for<br />

consistent quality in the production of mini tools<br />

In order to precisely grind microtools with extremely<br />

small diameters, an optimally coordinated<br />

overall cutting system is required. One quality-determining<br />

piece in the mosaic is micro-filtration of the<br />

coolant.<br />

This is because the smallest impurities in the grinding oil<br />

or temperature fluctuations in the medium have a negative<br />

effect on the quality of the grinding result. The filter manufacturer<br />

Vomat from Treuen offers the necessary filter technology<br />

to meet the specific performance requirements in<br />

micro tool production: Vomat filters deliver highly filtered<br />

grinding oil in purity class NAS-7 (3-5 µm) over a long application<br />

period. In addition, they ensure precise control of the<br />

coolant temperature.<br />

The continuing trend towards miniaturization of devices<br />

and components in various industries requires the use of<br />

extremely small and high-precision tools in production. For<br />

example, in order to grind reliably drills, milling cutters and<br />

gauges etc. with their wafer-thin shanks and filigree geometries<br />

in large-scale production, the production conditions<br />

and technologies in conjunction with comprehensive quality<br />

assurance play a decisive role. State-of-the-art grinding,<br />

measuring and edge preparation technologies, ideally in temperature-constant<br />

production halls, complement each other<br />

perfectly and result in mini tools that meet the extreme<br />

requirements of the industry in terms of surface quality and<br />

concentricity.<br />

The filter<br />

manufacturer Vomat<br />

offers ultra-fine<br />

filtration technology<br />

that provides clean<br />

coolant media in<br />

NAS-7 quality with<br />

high control accuracy<br />

and is therefore<br />

particularly suitable<br />

for the production<br />

of miniature tools.<br />

“An important factor in this sensitive production environment<br />

is ultra-fine filtration of the cooling lubricants”, as<br />

Steffen Strobel, sales manager at Vomat, points out. “When<br />

grinding microtools, contaminated or insufficiently filtered<br />

cooling lubricants can have a sensitive effect on the grinding<br />

result. Even minimal temperature fluctuations in the cooling<br />

lubricant pose a major threat to the final quality as they can<br />

have a negative effect on the expansion behavior of machine<br />

components and tool substrates. Vomat’s filter technology is<br />

designed to eliminate precisely such disturbing factors and<br />

ensure optimum filtration.<br />

Trend-setting filter technology<br />

Vomat filters separate 100 % dirty and clean oil in full flow.<br />

This means that the tool manufacturer can always work with<br />

clean cooling lubricants. In addition Vomat systems carry<br />

out backflushing as required. The degree of contamination of<br />

each individual filter element is monitored, and if a defined<br />

value is exceeded the backflushing process is automatically<br />

initiated.<br />

Meanwhile the other filter elements ensure a continuous<br />

supply of clean oil in cleanliness class NAS-7 (3-5 µm). This<br />

advanced capacity control of the filter system helps to optimize<br />

energy consumption and thus lower operating costs for<br />

the grinding process. Precise temperature monitoring of the<br />

grinding oil with a control accuracy of +/- 0.2 K ensures constant<br />

optimum temperatures of the coolant media.<br />

The design advantages of the Vomat filters used play an important<br />

role in process-reliable production with reproducible results,<br />

especially the high control accuracy and precise temperature<br />

monitoring of the grinding oil when grinding microtools<br />

Steffen Strobel: “If the tool manufacturer relies on the<br />

latest grinding technology for grinding microtools, he cannot<br />

do without forward-looking fine filtration. Only in this<br />

way he can produce the high qualities that the industry<br />

requires.”<br />

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

48 no. 1, February <strong>2024</strong>

components<br />

Motorview process visualization system proves its<br />

worth in the semiconductor industry<br />

A core topic of Industry 4.0 is and remains the<br />

monitoring and control of manufacturing and<br />

machining processes. MotorView, developed by<br />

BMR elektrischer und elektronischer Gerätebau GmbH<br />

(BMR for short) in 2020, offers a powerful solution for<br />

integrating a process monitoring system for converters<br />

and motors and is suitable for all applications in<br />

which a spindle converter system is used.<br />

These include milling machines, for example where several<br />

operations are often carried out with different milling cutters<br />

and it is particularly important to track each individual<br />

processing step directly. MotorView has already proven itself<br />

successfully in various applications and has been in use at<br />

Schaeffler Aerospace for many years.<br />

First application in wafer production<br />

The BMR process visualization system, which is worldwide<br />

unique in terms of its efficiency, flexibility and compactness,<br />

is now being used for the first time in the semiconductor industry,<br />

specifically at Genauigkeits-Maschinenbau Nürnberg<br />

GmbH (G&N for short). The company develops and produces<br />

precision surface grinding machines for the machining of<br />

metals, ceramics, silicon and other materials where machining<br />

is particularly demanding. Since fall last year, almost all<br />

automatic machines and new developments have been offered<br />

together with MotorView. The detailed test phase directly on<br />

MotorView<br />

Grinding at G&N<br />

site in production has already shown that the BMR system<br />

continuously achieves repeat accuracies of 5 μm on average<br />

when grinding wafers. A further advantage became apparent<br />

when retrofitting existing machines on site, as the motor<br />

phases only had to be looped through the device once, eliminating<br />

the need for time-consuming and space-consuming<br />

retrofitting.<br />

“With this BMR system we offer our customers added safety<br />

and saved time”, says G&N managing director Hermann<br />

Moos. “This new application shows that it is worth to use in<br />

a wide range of high-tech applications”, explains Stephan<br />

Brittling, managing director of BMR, responsible for coordinating<br />

the test phase and customer support on site. “Also<br />

here our product will soon be amortized”, continues Stephan<br />

Brittling.<br />

MotorView consists of two components and is therefore<br />

easy to install: the sensor part is clamped or looped into<br />

the motor cables between converter and driven motor. As a<br />

result the motor phases run via the device, which records and<br />

stores all information about voltages and currents without<br />

affecting the process. The display part is connected via<br />

cable and graphically displays the recorded load status of the<br />

spindle. Digital and serial interfaces are available for communication<br />

and integration with the machine control system.<br />

In the long run the system contributes to cost reduction in<br />

production in the sense of “predictive maintenance”. For<br />

example it enables the user to change tools in good time by<br />

detecting reductions in cutting performance due to blunt<br />

tools at an early stage. Furthermore it immediately detects<br />

bearing fade of the spindles, the failure of a motor cable, the<br />

detection of control oscillations or parameterization errors in<br />

the drive system.<br />

further information: www.bmr.gmbh<br />

no. 1, February <strong>2024</strong><br />


components<br />

Multisensor technology<br />

perfectly integrated<br />

The VideoCheck® S from Werth Messtechnik now offers even<br />

greater flexibility. The multisensor coordinate measuring machine<br />

can additionally be equipped with up to three independent sensor<br />

axes and a stepless, multisensor-capable rotary/tilt head.<br />

With the high-precision machines of the Werth VideoCheck® series the<br />

potential of even the most accurate sensors can be fully exploited. Werth offers<br />

unique high-precision sensors, as the patented Werth Fiber Probe® 3D<br />

or the Werth Interferometer Probe. The proven multi-ram concept for maximum<br />

flexibility when using multisensor technology is now also available<br />

for the smallest machine in the series, the VideoCheck® S. The new machine<br />

concept makes it also easy to retrofit suitably prepared purely optical or<br />

purely tactile machines with multisensor technology.<br />

This means that the accessibility of workpiece geometries is no longer restricted<br />

by other sensors or accessories. The independent sensor axes enable<br />

fast measurements without sensor changes. Since the axes with the nonactive<br />

sensors are outside the measuring range, the risk of collision is minimal.<br />

Sensor changing stations are no longer necessary, so that the measuring<br />

range can be used without restriction. It is possible to remove the changing<br />

stations from the measuring volume after the sensor change using the machine<br />

axes, but that time is also eliminated.<br />

Werth coordinate measuring machines offer high flexibility with various<br />

options. With the Werth Multisensor System different sensors can be<br />

swapped in at the same position in front of the image processing beam<br />

path. This means that the combined multisensor measuring range can<br />

be used without restriction, even with additional sensors, and the risk of<br />

Fast multisensor<br />

measurements<br />

without restrictions<br />

with the multi-ram<br />

concept on the<br />

VideoCheck® S<br />

collision is minimal. The new, multisensorcapable<br />

Werth Rotary Tilt head enables fast,<br />

stepless positioning of sensors. For example,<br />

very steep flanks can now be measured with<br />

optical sensors as well. The eccentric probe<br />

mounting also allows the use of rotary/tilt<br />

heads on smaller machines. Workpiece rotary<br />

or workpiece rotary/tilt axes can be mounted<br />

in any direction. The multi-ram concept optimizes<br />

accessibility and minimizes the risk<br />

of collision.<br />

The new machine is suitable for mediumsized<br />

workpieces with tight tolerances and<br />

different geometric properties that require<br />

the use of multisensor technology. Examples<br />

include large plastic housings of automotive<br />

electronics, cutting inserts, micro hobs, shaft<br />

tools, optical lenses or dental implants.<br />

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

Ultra black laser marking for medical technology<br />

US-product premiere at the trade show: FOBA Laser Marking<br />

+ Engraving Solutions presented its ultrashort pulse laser for ultrablack<br />

laser marking for the first time in the United States at MD&M<br />

West (Anaheim, CA, February 6-8, <strong>2024</strong>).<br />

“After the successful premiere in Europe we are proud to present our new<br />

product to our customers in the USA. The FOBA ultrashort pulse laser produces<br />

deep black markings that are particularly gentle on materials, making<br />

it a real asset for the medical technology market in particular,” reports<br />

Philipp Febel, head of product management at FOBA.<br />

The ultrashort pulse laser F.0100-ir marks in a deep, matt and non-reflective<br />

black without generating significant heat on the workpiece. Through<br />

further processing steps, such as passivation, the marking remains reliably<br />

legible and corrosion resistant. Due to the very short pulses down to the<br />

femtosecond range, together with high pulse energies, the system marks<br />

stainless steels, titanium and a variety of plastics. The compact laser can be<br />

integrated into FOBA’s M-series; it was shown at the trade fair in an M2000<br />

workstation.<br />

“We want to<br />

actively support our customers<br />

with the current and upcoming<br />

UDI labeling standards,” says Jeffrey A Kniptash,<br />

sales manager Americas at FOBA. According<br />

to FDA regulations all reusable and reprocessed<br />

medical devices must bear a directly<br />

marked UDI (unique device identification),<br />

meaning a unique numeric or alphanumeric<br />

code. “We offer expert advice on this topic,<br />

and thus facilitate the implementation and<br />

validation of a secure laser marking process,”<br />

continues Jeffrey A Kniptash.<br />

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

50 no. 1, February <strong>2024</strong>

impressum<br />

ISSN 2628-5444<br />

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Four issues per year<br />

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ALLTEC Angewandte Laserlicht<br />

Technologie GmbH .................50<br />

ANCA Pty LTD .....................18<br />

BMR elektrischer und elektronischer<br />

Gerätebau GmbH ..................49<br />

CERATIZIT ........................23<br />

DN Solutions Europe GmbH ......... 20<br />

EMAG GmbH & Co. KG ..............31<br />

EMUGE-Werk<br />

Richard Glimpel GmbH & Co. KG ...15<br />

Fritz Studer AG ................. 34, 38<br />

Gebrüder Heller<br />

Maschinenfabrik GmbH ........ 19, 40<br />

Global Industrie <strong>2024</strong>. ...............22<br />

Hartmetall-Werkzeugfabrik<br />

Paul Horn GmbH ..................10<br />

Huttelmaier GmbH . . . . . . . . . . . . . . . . . .43<br />

Hyperion Materials & Technologies,<br />

Inc. ...............................11<br />

KAPP GmbH & Co. KG. . .............32<br />

Lach Diamant Jakob Lach<br />

GmbH & Co. KG ...................26<br />

Liebherr Verzahntechnik GmbH . .... 42<br />

company finder<br />

MAPAL Fabrik für Präzisionswerkzeuge<br />

Dr. Kress KG .................. 12, 25<br />

Mikron AG, Division Tool .............6<br />

oelheld U.S., Inc. ................... 48<br />

Okuma Europe GmbH ...............21<br />

OTEC Präzisionsfinish GmbH ........37<br />

Platinum Tooling Technologies, Inc ....19<br />

RINGSPANN GmbH ................ 46<br />

SPR Abrasives GmbH ................16<br />

TRUMPF SE + Co. KG ...............45<br />


UNITED GRINDING Group ........ 24<br />

VDW Verein Deutscher<br />

Werkzeugmaschinenfabriken e.V.. ..17, 22<br />

VOLLMER WERKE Maschinenfabrik<br />

GmbH . ........................ 23, 36<br />

WEILER Abrasives GmbH. .......... 24<br />

Werth Messtechnik GmbH. ...........50<br />

ZECHA Hartmetall-Werkzeugfabrikation<br />

GmbH. ...........................14<br />

Zeller+Gmelin GmbH & Co. KG. ..... 44<br />

The articles contained in this magazine,<br />

including the illustrations, are subject<br />

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copyright © <strong>2024</strong> Dr. Harnisch Publications<br />

advertising index<br />

Boehlerit GmbH & Co. KG ...............................................page 13<br />

Kapp GmbH & Co. KG ..................................................page 11<br />

Lach Diamant Jakob Lach GmbH & Co. KG ....................... inside front cover<br />

Mikron AG, Division Tool ............................................front cover<br />

SPR ABRASIVES .................................................... back cover<br />

no. 1, February <strong>2024</strong><br />




• Trusted global superabrasives supplier<br />

• Setting new industry standards for excellence<br />

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sprabrasives.com • contact@sprabrasives.com • +49 33205 74690

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