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 ■
»CONTOUR PROFILED«<br />
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 />
3
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 />
5
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 />
LASERTEC 30 DUAL SLM<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 />
7
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 />
9
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 />
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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 />
www.boehlerit.com
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 />
15
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 />
17
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 />
19
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 />
21
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 />
23
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 />
new UNITED GRINDING<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 />
25
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 />
27
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 />
LACH-SPEZIAL-WERKZEUGE (LACH Special Tools),<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 />
29
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 />
31
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 />
33
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 />
35
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 />
37
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 />
39
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 />
41
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 />
43
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 />
45
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 />
47
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 />
49
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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company finder<br />
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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 />
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GmbH . ........................ 23, 36<br />
WEILER Abrasives GmbH. .......... 24<br />
Werth Messtechnik GmbH. ...........50<br />
ZECHA Hartmetall-Werkzeugfabrikation<br />
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Zeller+Gmelin GmbH & Co. KG. ..... 44<br />
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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 />
51
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