hpt 2024 #2

ISSN 2628-5444 

high precision tooling 

Machine Tools, PCD, PVD, CVD, CBN, Hard Metal 2024 – 2 

■ Imperfect diamonds for quantum technology ■ Material behavior and microstructure of hardmetal ■ 

■ GrindingHub preview ■ Looking back at TMTS 2024 ■ Component cleaning for the entire production chain ■

Stop long Chips 

»IC-plus« world´s best (pat.) 

chipbreaker 

Visit us at 

AMB · Hall 3, Stand D11 

Grinding Hub · Hall 7, Stand D70 

...a must have for turning aluminium 

® 

® 

tradition.passion.innovation. since1922 

office@lach-diamant.de · www.lach-diamant.de

editorial 

Eric Schäfer 

editor-in-chief 

Each little step counts 

This doesn’t just apply to our physical fitness. When it 

comes to sustainability in manufacturing, each little step 

counts. Green processes help protecting the environment, 

reducing costs and staying competitive in the long run. 

For example by using renewable energy or recycled 

materials. 

Brings solutions 

to the surface. 

The meeting point for grinding technology. 

Stuttgart,Germany 

14-17/05/2024 

The latter is an important issue for Ceratizit Austria 

GmbH, which the company also passes on to its 

customers with its “upGrade” grades. Ceratizit’s carbide 

product line is characterized by a conscious use of energy, 

resource efficiency, economical use of raw materials and 

the recovery of secondary raw materials in the form of 

recycled carbide cutting tools, which leads to a drastic 

reduction in the CO 2 footprint of the products. In order 

to meet the quality requirements, Ceratizit has subjected 

its new carbide grade, which consists of 99 % high-quality 

secondary raw materials, to extensive machining tests. 

Read more about this on page 16 of this issue. 

Sustainability is increasingly becoming an integral part 

of corporate strategy. GrindingHub, the international 

trade fair for grinding technology, which will take place 

in May for the second time, will demonstrate this with 

numerous examples. These range from digital solutions 

in mechanical engineering and the resource-saving use 

of cooling lubricants to the implementation of AI in 

machine software. 

With its focus on “digital transformation” and “green 

transformation” the TMTS trade show in Taiwan also 

picked up on this trend towards sustainability. hp tooling 

was on site and provides information in a special section. 

Ultimately they are many small steps around the world 

that move us forward on the path to sustainable business 

and thus to a sustainable future. 

Eric Schäfer 


UGO* 

fascinates all 

visitors. 

* 

Unknown Grinding Objects 

In Zusammenarbeit mit 

In cooperation with 

grindinghub.de 

Trägerschaft 

Sponsorship

table of contents 

cover story 

Precision for high-performance lenses 6 

materials & tools 

“Future for today” 8 

Perfect – imperfect diamonds for quantum technology 10 

Better performance and new cutting solutions 12 

New standards in efficient joinery of timber construction elements 14 

A look behind the scenes of “upGrade” CT-GS20Y 16 

processes 

Surface finishes – fine and polish grinding 28 

Change– before you have to! / The new era of clean-tech machining 31 

Generating grinding of double helical gears 32 

Innovative milling technology for weld seam preparation 34 

machining center 

Perfecting the entire machining process on the stator housing 36 

A new era in casting and machining technology 37 

Empowering e-mobility industry 38 

High precision grinding for a sustainable and digitalized future 40 

components 

Resource-saving ultra-fine filtration technology for regrinding precision tools 43 

A customized grinding solution for tap manufacture 44 

AI machining strategies for 3+2 axis CNC machines 45 

Efficient, innovative and sustainable component cleaning for the entire production chain 46 

TMTS 

Five major trends at Taiwan International Machine Tool Show 2024 47 

news & facts 18 

fairs 5, 27 

impressum & company finder 51 

4 no. 2, April 2024

fairs in alphabetical order 

AMB Stuttgart, Germany 

(September 10-14, 2024) 

bauma Shanghai, China 

(November 26-29, 2024) 

CMTS Toronto, Canada 

(Sept 29-Oct 2, 2025) 

EPHJ Geneva, Switzerland 

(June 11-14, 2024) 

FABTECH Toronto, Canada 

CANADA (June 11-13, 2024) 

FEIMEC São Paulo, Brazil 

(May 7-11, 2024) 

current status 

2024 


2025 




FILTECH Cologne, Germany 


GrindingHub Stuttgart, Germany 

(May 14-17, 2024) 

GrindTec Leipzig, Germany 

(March 11-14, 2025) 



2025 

hi Tech & Industry Herning, 

Scandinavia (Sept 30-Oct 2, 2025) 

Denmark 

2025 

IMT Brno, Czech Republic 

(October 8-11, 2024) 

IMTS Chicago, USA 

(September 9-14, 2024) 

JIMTOF Tokyo, Japan 


MACH-TECH and Budapest, Hungary 

INDUSTRY DAYS (May 7-10, 2024) 

METALEX Bangkok, Thailand 


MOULDING Stuttgart, Germany 

EXPO (May 6-9, 2025) 

sps Nuremberg, Germany 


STEELFAB Sharjah, United Arab 

(January 13-16, 2025) Emirates 

Stone+tec Nuremberg, Germany 

(June 19-22, 2024) 

Surface Stuttgart, Germany 

Technology (June 4-6, 2024) 

TIMTOS Taipei, Taiwan 

(March 3-8, 2025) 






2025 


2025 



2025 

trade fair dates as by middle of April 2024; we are not responsible for reliability of these dates 

no. 2, April 2024 

5

cover story 

Precision for high-performance lenses 

Optics for measuring systems, camera lenses and 

other high-performance optics require manufacturing 

precision in the range of a few µm. In order to ensure 

the best possible optical quality of such lenses, very 

high centering accuracy of the individual lenses in 

relation to each other is required. TRIOPTICS, based 

in Wedel near Hamburg, specializes in the manufacture 

of systems for lens centering, testing and alignment 

turning, among other things. 

For the precise turning of glass lenses mounted in brass or 

aluminum, TRIOPTICS relies at its Wetzlar site on diamondtipped 

ISO inserts from Paul Horn GmbH. 

Founded in 1991, TRIOPTICS develops and produces the 

widest range of optical measurement and manufacturing 

systems for the development, quality control and production 

of lenses, objectives and camera modules, setting standards 

in the field of optical measurement. The company’s quality 

standards focus in particular on the measuring accuracy of 

the devices and the user-friendly software. The systems include, 

for example, equipment for the inspection and assembly 

as well as the alignment turning of optical components. 

No wonder that TRIOPTICS has also established a branch in 

Wetzlar, the city of optics. “We have world-renowned manufacturers 

in the optical industry in Wetzlar. In addition to 

sales and service, we also offer contract alignment turning in 

small quantities”, explains branch manager Stefan Best. 

A collaboration based on trust: 

Stefan Best in conversation with Stefan Bachmann 

Alignment turning 

High-performance objectives consist of a precise internal 

structure of several lenses. Depending on the objective lens, 

ten or more individual lenses may be included. If just one lens 

in this entire system is not correctly aligned, this affects the 

optical performance of the objective. Tolerances of a few µm 

can be crucial. To achieve this the metal mounts of the lenses 

must be accurately turned. During the alignment turning of 

objectives, the mount edge and the flange surfaces of mounted 

spherical, aspherical and cylindrical lenses are machined so 

that the axis of symmetry of the mount coincides with the 

optical axis of the lens. The alignment lathes combine a centration 

measuring system with a high-precision lathe. This 

makes it possible to adjust and control all relevant parameters, 

such as the diameter of the mount or the distance between 

the lens and the contact surfaces of the mount, when 

processing the frame. The high-precision measurement of the 

decentering and the precise machining of the mount avoid 

time-consuming, iterative alignment steps in the overall 

optical system, resulting in adjustment-free lens assembly. 

The efficient adjustment lathes from the ATS family are 

characterized by their versatility and user-friendliness. The 

various types allow adaptation to different workpiece sizes 

as well as the required accuracy. With its CNC capabilities, 

the ATS-C type can be quickly integrated into existing production 

environments as a fully-fledged lathe. It can machine 

small, mounted lenses within short cycle times. 

The achievable quality in terms of surface finish and 

precision is the main reason for choosing Horn tools 

“I have known Horn tool systems for a very long time and 

used them in my previous job at a large optics manufacturer 

here in Wetzlar”, says Best. After moving to TRIOPTICS, 

tools from the Tübingen-based tool specialist are still his 

first choice. Best is in frequent contact with Horn sales representative 

Stefan Bachmann. “At Horn, we have a high level 


cover story 

of expertise in tools for the optical industry 

and can show how precisely our tool systems 

can be used and the high quality that 

can be achieved”, says Bachmann. The alignment 

turning of the mounted lenses is in the 

IT 6 tolerance class, but according to Best the 

trend in high-performance optics is moving 

strongly in the direction of IT 3 and IT 4 

quality, i.e. tolerances of less than 5 µm, depending 

on the mount diameter. Another important 

feature is the surface quality of the 

plane and lateral surfaces. “Surface quality 

of Ra 0.4 µm to 0.8 µm are usually required”, 

says Best. The fine chips are vacuumed away 

during the turning process so that the sensitive 

lenses are not damaged. 

Diamond-tipped tools 

In order to achieve the required surface finish, 

the CVD-D diamond grade is used for alignment 

turning, which is brazed onto an ISO insert. 

“We opted for CVD diamond because the 

cutting edge of this grade can be prepared so 

that it is very sharp and fine. This fine insert 

means that the required surface finish can be 

maintained reliably in series production”, explains 

Bachmann. Thanks to the nick-free and 

geometrically-optimized inserts, the CVD-D 

diamond can be used for everything from 

roughing to fine finishing. As the tools enable 

accurate contour machining in the µm range, 

there are significant cost advantages compared 

to grinding and spark erosion, for example, 

CNC adjusting lathe ATS-C for 

processing small, mounted lenses in short cycle times 

and greater manufacturing flexibility. The surface structure is also superior 

to, or at least equivalent, to these two processes in terms of roughness, 

polishability and corrosion behavior. 

The lens mounts are adjusted with only very small infeed settings, which 

are usually less than a tenth of a millimeter, as the actual glass lens is already 

glued into the frame to a tight tolerance using a special bonding technique. 

“Alignment turning is therefore the very final step for a perfectly aligned 

optical axis. The achievable tool life, if the inserts are handled correctly, is so 

long that it is almost impossible to quantify”, explains Best, who continues: 

“However, the high quality in terms of surface finish and precision is the ultimate 

reason we choose tools from Horn.” 

The TRIOPTICS machine is used for 

measurement, adjustment and 

alignment turning of optical lenses 

Monocrystalline diamonds 

In addition to CVD diamonds, monocrystalline diamonds (MCD) are also 

used in alignment lathes and in the optics industry in general. They enable 

ultra-precision machining to within nanometers and produce mirror-like 

surface finishes that can only be measured via light refraction. For example, 

MCD-equipped tools are used for turning spectacle lenses, contact lenses 

and other optical glass lenses or for alignment turning in the semicon ductor 

industry. In the case of varifocal spectacles, they enable the free form of the 

spectacle lens to be turned in order to create different prescription areas 

on the surface. The quality of the tool cutting edge plays a decisive role in 

producing surfaces with a mirror finish. Final grinding or polishing of the 

MKD inserts is akin to craftsmanship. Similar to the cutting of a diamond 

for jewelry, the finishing of a tool edge for high-gloss machining is done by 

hand using grinding pliers. Air-bearing grinding tables with a solid granite 

top provide optimum conditions for grinding the inserts. A microscope with 

200x magnification is used for visual inspection. Under this magnification, 

the cutting edge must be absolutely free of nicks. 

further information: www.horn-group.com 


7


“Future for today” 

LACH DIAMANT, the manufacturer of diamond 

and CBN tools and grinding wheels from Hanau, is 

purposefully positioned for “GrindingHub”, both 

with a conventional as well as with a “Future for today” 

portfolio, and is therefore the ideal partner. 

Even today, LACH DIAMANT with its over 100 years of 

experience (founded in 1922) is traditionally well recommended 

for its grinding service of natural diamonds, for 

the maintenance of single-point dressing and profile diamonds 

(e. g. the Diaform diamond chisel); followed by multipoint 

dressers and the high-tech diamond dressing plate 

“Dia-Fliese-perfect”. 

“ICplus” world’s best – 

a must-have for 

turning aluminum 

grinding processes. Examples: form cutting inserts (threads), 

roughing cutters with milled profiles, cutters/slicers for the 

food industry, profile milling tools (concave and convex etc.); 

everything for deep grinding. 

LACH DIAMANT maintenance service for single-point 

dressing and profile diamonds; in the picture 

Annabelle Lach, instructed by master grinder Mr. Kliem 

For profile dressing in series production ask LACH 

DIAMANT about diamond precision dressing rolls and 

“drebojet®-plus” CNC dressing wheels. For the grinding of 

hardened steels, HSS, carbides, and ceramics, customers 

can choose from diamond and boron nitride CBN grinding 

wheels; all of which are individually customized to the 

respective grinding process and in regards to all bond varieties 

– consultations focus on maximal tool life and efficiency. 

The large variety of resin-bond, ceramic, electro-plated 

and for instance hybrid-diamond and CBN grinding wheels 

is crowned by an unique development, the metal-bond “contour-profiled” 

grinding wheel for profile grinding in series 

production. 

“contour-profiled” diamond and CBN grinding wheels 

make it possible to skip several, previously necessary, costly 

Specially developed metal bonds and the unique manufacturing 

process of the “contour-profiled” grinding wheels 

make this exemplary performance possible; externally evident 

from multi-layered “spikes” protruding from the metal 

bond. Depending on diamond or CBN grain size (from 15 to 

approximately 650 micron), the desired profile is “turbo”-cut 

into the respective material with a surface quality of up to 2 µ. 

Regarding their mode of operation, “contour-profiled” diamond 

and CBN grinding wheels are comparable to a grinding 

wheel with electro-plated or attached abrasives. These 

grinding wheels guarantee multiple times the stability and 

performance of each grain retained within the metal matrix. 

In addition “contour-profiled” diamond and CBN grinding 

wheels can be re-profiled up to 35 times, due to their multilayered 

coating (experience shows these results now even for 

complex profiles). 

Moreover LACH DIAMANT provides visitors with another 

comprehensive program portfolio designed for mould and 

tool construction – starting with the diamond needle file, 

diamond and CBN grinding wheels for internal grinding 

as well as lapping and finishing with diamond pastes and 

the one-of-a-kind diamond spray “MF” program (“MF” for 

Micro-Finish). 

The grinding program is completed by a selection of special 

polycrystalline cutting tools; among them the highly recommendable 

and must-have choice for aluminum turning, 

“IC-plus” world’s best (patented) chip breaker. For turning 

hardened steels, for example the dreborid-G® CBN cutting 

insert “duo-power” with doubled performance. 

GrindingHub 2024, hall 7, booth D70 

further information: www.lach-diamant.de 



For difficult applications 

The carbide grade SG66 is available for all common Horn insert systems. The 

in-house coating also enables a short delivery time for special tools. SG66 cannot 

replace the CBN grade. Horn has, however, filled the gap for particularly difficult 

groove turning applications. In comparison, the CBN grade achieves twice the cutting 

speed and more when machining through-hardened materials. 

further information: www.horn-group.com 

The carbide grade SG66 is available 

for all common Horn insert systems 

visit us at: 

hall 9, booth 9D16 

Hard shell – soft core: Horn has 

developed the new SG66 grade for 

turning workpieces with different 

hardness zones. When machining 

turned parts with hardened surface 

layers or with an interrupted 

cut, users quickly reach the limits 

of CBN inserts. This is where the 

new grade comes in. 

In combination with the fine-grain 

carbide, the aluminum-titanium-silicon 

chromium nitride layer delivers 

high performance when machining 

hardened steels up to 58 HRC. The 

maximum allowable temperature is 

1,200 degrees Celsius (2,192 degrees 

Fahrenheit). Due to the high flexural 

strength of the carbide substrate interrupted 

cutting is also possible in hardened 

materials. In addition to hard 

machining, the carbide grade is also 

suitable for reliably processing highly 

temperature resistant and other difficult-to-machine 

steel alloys.


Perfect –imperfect diamonds 

for quantum technology 

HaiNan Neocrystech Co., Ltd was founded October 

2023. It offers quantum-grade diamond products that 

contain controlled levels of nitrogen-vacancy (NV) 

centers, including high-quality single and ensemble 

NV-centers. Diamonds with negatively charged nitrogen-vacancy 

(NV) centers have been attracting more 

and more attention in recent years. 

Due to the electronic spin and optical transition characteristics 

of NV-centers, diamonds with single or ensemble NVcenters 

have been used in quantum information processing 

and precision detection. 

as follows: 1) the initial state is quantum pure, which is easy 

to initialize, manipulate, and readout; 2) the quantum coherence 

time of the spins is long; 3) it shows ultra-high sensitivity 

and technical resolution; 4) it can be operated at room temperature 

and atmospheric conditions, which is good for the 

compatibility with biological samples; and 5) it achieves the 

quantum coherent manipulation of spins in low-noise, highefficiency, 

and fast manner by the high fidelity quantum spin 

state regulation technology. 

Isolated NV-center show a simple and stable spin level 

structure which is available as a qubit. In addition diamonds 

unique optical properties enable convenient quantum state 

optical initialization and readout. Recent years have seen 

a lot of progress in quantum computing and communication. 

The most promising application of diamonds with NVcenters 

lies in quantum sensing in weak magnetic field. It is 

widely recognized that NV-center magnetometry quantum 

sensors are most likely to be commercialized. 

NV-based magnetic measurement techniques have many 

advantages over traditional ones, such as hall effect sensors, 

superconducting quantum interference devices (SQUIDs), 

vapor cells and magnetic microscopes. The advantages are 

figure 2 

Precision measurement based on NV centers 

(CIQTEK) 

figure 1 

Crystal structure and 

energy level structure 

of NV center: 

(a) crystal structure 

(b) energy level structure 

(Wang Cheng-Jie, Shi Fa-Zhan, Wang Peng-Fei, Duan Chang-Kui, Du Jiang-Feng. 

Nanoscale magnetic field sensing and imaging based on nitrogen-vacancy center 

in diamond. Acta Phys. Sin., 2018, 67(13): 130701. doi: 10.7498/aps.67.20180243) 

What is NV-center in diamond? 

NV-center is a special type of luminescent point defect in a 

dia mond, where a nitrogen atom replaces a carbon atom with 

a vacancy formed in close proximity. The NV-center usually 

exhibits two charge states, NV- in a negative charge state and 

NV0 in an electrically neutral state. The negatively charged 

NV-center (NV-), whose vacancy provides four unpaired 

bonded electrons, together with one electron contributed 

by the nitrogen atom and one additional captured electron, 

forms a system which can be regarded as an electron spin and 

as a qubit. This spin system shows excellent light-detecting 

magnetic resonance properties (NV- is referred to as NV in 

all the following text). 

How can NV-center be used in magnetic detection? 

Figure 1 shows the energy level structure of the NV-center in 

diamond at room temperature. The ground state of the nitrogen 

vacancy center is a spin triplet state (ms = 0, ±1). In the 

ground state, ms = -1 and ms = 1 are merged in the absence of 

magnetic field. 

As shown in figure 1b, a 532-nm laser is usually used to 

pump the NV-center from a ground state to an excited state. 

The electrons on the ground state of the NV-center absorb 

the energy to jump to the excited state. However, due to the 



figure 3 

CW-ODMR 

(CIQTEK) 

figure 4 

Neocrystech 

product range 

instability of the electrons on the excited state, the electrons 

undergo a jump to the ground state with spontaneous 

photon emission. The fluorescence of the spin ms = 0 state 

is brighter than that of the ms = ±1 state, so with the aid 

of fluorescence confocal microscopy, it is possible to read 

out individual spin states (quantum states) of NV-centers 

by counting the fluorescent photons. Different lengths of 

lasers can achieve the initialization and readout of the NV 

quantum state. 

To read out the NV-center electron spins, optically detected 

magnetic resonance (ODMR) can be used. When applied 

in magnetic field, the merged state will be separated, 

and under the action of the continuous wave spectrum, two 

wave peaks will appear as shown in figure 3. By measuring 

the distance between the two peaks, we can calculate the 

size of the magnetic field. 

Application of NV-centers in precision detection 

The energy level of NV-center is sensitive to external samples. 

By reading out the state of the electron spins of 

NV-centers, we can calculate the direction and the size of 

the magnetic field, the information of the electric field and 

the change in temperature. 

In addition magnetic imaging through NV-based 

sensors is now widely applied in life science. Scanning 

magnetic imaging is based on single NV-center diamonds, 

while wide-field magnetic imaging is based on ensemble 

NV- center diamonds. Ensemble NV magnetic imaging is 

found to have more potential for wide-field and real-time 

imaging, thus showing greater applicability in the field of 

cellular magnetic imaging research. 

Application of NV-centers in 

quantum information processing 

The NV-center, as a quantum qubit, can help achieve a new 

generation of information processing under quantum law. 

Realizing the quantum algorithm is the core goal of quantum 

computing. The quantum algorithm based on NVcenter 

spin has been experimentally proven that quantum 

computing has incomparable advantages over classical 

computing. At the same time, because NV-center can 

produce a single photon, it can be used for quantum key 

distribution and establish remote quantum entanglement 

in quantum communication. 

Neocrystech product range 

HaiNan Neocrystech Co.,Ltd, offers quantum-grade diamonds 

that contain deliberate and controlled levels of NV-centers, 

including high-quality single and ensemble NV centers. 

The exclusive production features an internally dispersion 

of single NV-centers (SNV) in a density between 10 and 300 

per 26000 µm², with typical spin coherence times (T2) exceeding 

140 µs and a long T2* of 1~3 µs. The ENV diamonds 

contains high density NV-centers varying from 500 ppb to 

2 ppm, with T2 ranging from 100 to 200 µs and T2* of 0.5 µs. 

HaiNan Neocrystech Co.,Ltd offers customized diamonds 

with major {100},{111} or {110} in different densities. 

further information: www.neocrystech.com 

Precise and 

productive 

CBN profile grinding discs 

Liebherr-Verzahntechnik GmbH 

One-, two- or three-ribbed CBN profile grinding 

discs for internal gears 

– High-quality internal gears for low-noise use in gearboxes 

– Increased load capacity due to the high residual compressive stresses with 

CBN grinding 

– Individual grain sizes for different applications 

– Shorter grinding times 

– Roughing and finishing in a single process 

– Longer tool life 

– Time-consuming dressing not necessary with CBN tools 

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

GrindingHub, Stuttgart 

14-17. May 

Hall 7, Booth B36


Better performance and 

new cutting solutions 

Also in India the machining sector is growing 

steadily, and high-performance precision tools are in 

hot demand. Accusharp is one of the leading Indian 

tool manufacturers. In order to consolidate and expand 

its market position the company from Pune relies on 

high manufacturing know-how and modern technologies. 

With the CC800® HiPIMS from CemeCon installed 

in November 2021, Accusharp can now significantly 

increase the performance of its tools and open 

up new markets. 

Accusharp Cutting Tools Pvt. Ltd., based in Pune, India, 

develops and manufactures special cutting tools made of 

HSS and carbide for a wide range of industries, such as automotive, 

engineering, textile, energy and steel. The company 

is one of the largest manufacturers of cutting tools in 

the western part of India and the highest quality is their goal. 

Accordingly the latest tool grinding machines and the appropriate 

optical measuring technology are in use. As a logical 

next step the company invested in a turnkey in-house coating 

plant. This enables Accusharp to map the entire process 

chain for the production of cutting tools in-house and emphasizes 

the company’s role as an innovation leader. 

High-end technology for India and the world 

In the past Accusharp had its precision tools coated by various 

partners. Unfortunately the tool life and productivity 

of the tools often varied here. This was not acceptable to the 

experts. So the company decided to invest in its own coating 

line to take quality control into its own hands. “CemeCon 

has been present on the Indian subcontinent for almost 15 

years. Our customers appreciate the high quality of the coating 

and the service that CemeCon India provides. From a 

24/7 hotline service to its own spare parts warehouse, there 

is everything you wish for – above all, there is always a 

competent contact person available,” says Manish Adwani, 

Manish Adwani, managing director of CemeCon India 

With the CC800® HiPIMS from CemeCon, installed 

November 2021, Accusharp can now significantly increase the 

performance of its tools and will open up new markets 

managing director of CemeCon India. The best prerequisites 

for Accusharp to deepen the partnership with a turnkey 

project, so they decided to invest in a CC800® HiPIMS for its 

own coating production. 

So now the company is one of the few tool manufacturers 

in India to offer this high-end technology. “Accusharp has 

long been one of the key drivers in the Indian machine tool 

industry. We are widely known as an Indian manufacturer 

with a global business culture. This makes us the first choice 

for high-performance cutting tools for both regional companies 

and multinationals. By investing in HiPIMS technology 

and introducing coatings based on HiPIMS coating materials, 

we aim to further strengthen our market position. Our customers 

expect us to provide them with world-class solutions. 

This is another step on that path,” says Ilyas Shaikh, managing 

director of Accusharp Cutting Tools Pvt. Ltd. 

HiPIMS coatings increase performance significantly 

FerroCon® delivers convincing solutions for all types of 

carbon steel. For stainless materials and hard machining 

the new HiPIMS coating material SteelCon® is becoming 

the shooting star of the coating scene. “We have tested 

the HiPIMS coatings in various applications when machining 

different materials. The results are convincing: tool life 

has increased significantly in all cases – by 50 to 80 % depending 

on the application. Especially with hard materials 

that are difficult to machine, HiPIMS technology gives us 

decisive advantages in terms of precision,” says Ilyas Shaikh 

enthusiastically. 



And it was not only the technological advantages that convinced 

Accusharp; the installation of the turnkey HiPIMS 

coating line in November 2021 also ran in an exemplary 

manner despite the adverse circumstances worldwide. To 

support the company to the best of their ability, CemeCons’ 

experts used the full range of options – via online diagnostics 

and video stream, by phone and in person on site. With 

Manish Adwani as the most important link, the almost 15 

years of experience in India and the concentrated competence 

from Würselen, Germany, were thus perfectly bundled 

in the project. “We are more than satisfied with the service 

at CemeCon. Manish Adwani always finds a way to support 

us as quickly as possible with all questions relating to coating 

technology. We feel we are in good hands there. Our sales 

and application team is looking forward to having even better 

market shares with the addition of this new HiPIMS coating 

technology,” says Ayaz Shaikh, director of Accusharp Cutting 

Tools Pvt. Ltd. 

Sandip Patil and Vikash Yada, both production managers 

at Accusharp Cutting Tools Pvt. Ltd., agree: “We are very 

happy with the ease of operation of the coating unit and the 

training provided by Mr. Wadim Anselm and the CemeCon 

team from Germany.” 

Meeting future challenges as well 

Ilyas Shaikh is convinced that HiPIMS technology will give 

Accusharp a future-proof head start and will open up new 

markets: “Accusharp has always been a leader when it comes 

Accusharp was able to 

increase the service life 

of the precision tools 

by 50 – 80 % with the 

HiPIMS coatings, 

depending on the 

application 

to making machine tool solutions more economical and efficient. 

Thanks to HiPIMS coating technology we not only improve 

our existing products and get consistently good and reproducible 

results on new and reground tools, but we can also 

develop innovative cutting solutions for future challenges. 

A good example is micro-machining, which is becoming increasingly 

important. With HiPIMS we deliver matched premium 

coatings that are indispensable in the industry.” 

further information: www.cemecon.de 

SPR ABRASIVES 

STRONGER TOGETHER 

• Trusted global superabrasives supplier 

• Guaranteed quality through testing and certification 

• Setting new industry standards for excellence 

• In-house formulated and produced coatings 

• Commitment to innovation and customer collaboration 

• Premium products that exceed expectations 

• Exclusive Services including Laser and EDM cutting 

CBN powder • Resin Bond powder • Metal Bond powder • Micron powder • Natural Diamond powder PCD & PCBN 

CVD • HPHT Mono • Exclusive Services 

sprabrasives.com • contact@sprabrasives.com • +49 33205 74690


New standards in efficient joinery of 

timber construction elements 

Leitz, the world’s leading manufacturer of precision 

tools, presents a new, pioneering product: the 

HeliCut Monoblock. This innovative precision tool 

from the Oberkochen think tank sets new standards 

in the joinery of CLT cross laminated timber, glulam, 

solid wood panels, natural beams and more by meeting 

the highest demands in wood processing. 

The types of application in modern joinery are particularly 

wide-ranging nowadays. From cutting window cut-outs in 

CLT components to rebating, slotting or grooving to drilling 

positioning or anchor holes – each type of processing requires 

a special tool that should ideally not only be efficient, but 

also cost-effective, time-saving and long-lasting. An extreme 

challenge for anyone who has to keep an eye on the joinery 

process and the associated machining times and costs. 

The new HeliCut Monoblock from Leitz offers a solution 

which can be used for a wide range of applications such as 

drilling, pocket milling, tenoning and rebate milling in perfect 

quality. This eliminates time-consuming tool changes 

and downtimes. The monolithic design also makes the tool 

very stable and dampens vibrations. Some of the features and 

characteristics that make this tool system so attractive: 

inclined plunging: the tool enables inclined plunging – 

even at extreme angles. The innovative separate drilling/ 

chipping pocket optimises the chip flow, which in turn leads 

to less wear and makes the tool significantly longer-lasting. 

precise drilling: the special 

design of the tool enables precise 

drilling applications. Another advantage that 

significantly streamlines the overall joinery process. 

versatility: the new HeliCut Monoblock enables a wide 

range of applications with just one tool. Rebate processing, 

slotting, grooves and recesses – everything that is required 

for comprehensive joinery on a component (except 

V-grooves) can be realised with the help of this tool. 

spindle-friendly design, less vibration, less heat: 

the HeliCut Monoblock successfully solves repeated 

challenges caused by high cutting pressures and vibrations 

on the spindles. Compared to the competition, the Heli- 

Cut Monoblock impresses with less vibrations thanks to the 

short distance to the spindle system (lever). The optimum 

ratio of the overall tool length to the effective working length 

(180 mm) also contributes to improved stability. In addition, 

the reduction of the number of tooth rows results in less heat 

development and 25 % less power requirement as well as a 

reduced number of required turnblades. The result – longer 

tool and machine spindle life, lower costs and outstanding 

machining quality. The HeliCut Monoblock is now available 

on the market with a 40 mm diameter. All spindle adaptors 

for common machine types are compatible, including all 

common HSK adaptors and the S30 version. 

further information: www.leitz.org 

TIGRA will present carbide and 

diamond blanks at GrindingHub show 

TIGRA is the competent partner for versatile solutions 

made of carbide and ultra-hard cutting materials 

for tools for working metal, wood and composite materials. 

In order to always meet the application requirements of customers 

and optimize tool efficiency as best as possible, innovation 

and continuous improvement in the manufacture of a 

wide range of products are a top priority at TIGRA. 

At GrindingHub 2024 in Stuttgart TIGRA will be showcasing 

a wide range of carbide blanks that are used for working 

metal and composite materials after final machining by the 

customer: custom-made preforms according to the customer’s 

drawing, in a wide range of dimensions and geometries 

depending on the application, with insert seats and cooling 

holes, raw and ground carbide rods with or without cooling 

holes, standard milling cutter blanks with a wide range of 

cooling hole variants as well as carbide blanks and inserts for 

positive and negative inserts in the most common versions 

for subsequent PCD and PcBN tipping. 

In addition to carbide, the Bavarian-based company also 

offers PCD and PcBN products. Depending on the type of application 

and the material to be processed optimally matching 

grades are used to achieve the best results with standing 

and rotating tools. PCD and PcBN are always available in two 

versions: as blanks with different total and PCD/PcBN layer 

thicknesses and as laser or wire-cut segments with and without 

angles. They also offer CVD as blanks and segments in 

special grades for cutting and dressing tools. 


further information: www.tigra.de 


50 years of Innovation 

ANCA is celebrating its 50th anniversary, presenting a wealth 

of new products and solutions. Meet the people behind the 

success story and find out about exciting innovations at 

GrindingHub and further events in 2024. 

@AN 

@AN 

www.anca.com 

@AN 

@ANCACNCma 

Hall 7 

Stand A70 

@ANCACNCmachines 

@ANCACNCma 

@ANCACNCmac 

@ANCACNCmachines


A look behind the scenes of 

“upGrade” CT-GS20Y 

The Austrian research company Materials Center 

Leoben Forschung GmbH performed detailed investigations 

of the material behavior and microstructure 

of the “upGrade” hardmetal grade CT-GS20Y and the 

premium hardmetal grade CTS20D from Ceratizit. 

Sustainability is an important issue for Ceratizit Austria 

GmbH, which the company also passes on to its customers 

with its “upGrade” grades. Ceratizit’s hardmetal product line 

is characterized by conscientious use of energy, resource efficiency, 

economical consumption of raw materials and recovery 

of secondary raw materials in form of recycled cutting 

tools made of hardmetal, resulting in a drastic reduction of 

the CO 2 

footprint of the products. Like the premium hardmetal 

grade CTS20D, the new “upGrade” grade CT-GS20Y 

is a 10 % binder submicron hardmetal with a specified tungsten 

carbide grain size of 0.5 µm to 0.8 µm. This grade is the 

preferred choice for drilling and milling tools made of solid 

hardmetal and covers 70 % of this field of application. To fulfill 

the quality requirements, Ceratizit subjected its new hardmetal 

grade CT-GS20Y, which consists of 99 % high-quality 

secondary raw materials, to extensive machining tests. The 

test showed that the hardmetal grade CT-GS20Y is in no 

way inferior to the established premium hardmetal grade 

CTS20D in terms of achievable workpiece surface quality and 

resistance to tool breakage. Nevertheless, Ceratizit wanted to 

prove that secondary raw materials in their product do not 

influence deformation and creep properties under extreme 

thermal and mechanical loads. 

In the course of a joint research project, the research company 

Materials Center Leoben Forschung GmbH (MCL) investigated 

the mechanical properties, load and damage behavior 

of the hardmetal grades CT-GS20Y and CTS20D. 

High-resolution scanning electron microscopy (SEM) was 

used at the MCL to assess the microstructure. The SEM images 

of the sample surface were attained by scanning it with 

a focused electron beam. This made it possible to analyze the 

distribution of the tungsten carbides in the cobalt matrix. 

Figure 1 shows the microstructures of CT-GS20Y and CTS20D. 

Despite a high proportion of secondary raw materials in the 

CT-GS20Y grade, both hardmetal grades exhibit the same 

microstructure. In addition, the shape of the tungsten carbides 

was examined, which showed no difference between the 

hardmetal grades. 

Furthermore electron backscatter diffraction studies 

(EBSD) were carried out to extract crystallographic information: 

EBSD enables the differentiation of crystallographic 

phases and, for example, the characterization of grain sizes, 

orientations and boundaries. Figures 2a) and 2b) show crystal 

orientation images of the tungsten carbide grains of the 

Overviews and details of 

the microstructures of the 

“upGrade” grade 

CT-GS20Y in 

a) and 

b) 

Overviews and details of 

the microstructures of the 

premium carbide grade 

CTS20D in 

c) and 

d) 

figure 1 

Overviews and details of the microstructures of the “upGrade” grade CT-GS20Y as well as of the 

premium carbide grade CTS20D, taken at the MCL with a Zeiss Gemini SEM 450; the sample surface was polished 

with argon ions and the tungsten carbide appears light while the cobalt binder is dark gray 



figure 2 

Electron backscatter diffraction (EBSD) images of a) the “upGrade” grade CT-GS20Y, and 

b) the premium hardmetal grade CTS20D used to determine the grain orientation in the tungsten carbide grains, and 

c) the distributions of carbide grain sizes; the color legends show the orientation of the crystallites expressed via Miller indices 

“upGrade” grade CT-GS20Y and the premium hardmetal 

grade CTS20D. The tungsten carbide grain size distribution 

of both hardmetal grades derived from the EBSD images is 

shown in figure 2c). The carbide grain size distributions show 

values from the nanometer range up to single 2.0 µm grains. 

Approximately 5,000 carbides were recorded in both EBSD 

images, the majority of which are present in the specified 

submicron size between 0.5 µm and 0.8 µm. 

During use, for example, as tool materials in metal machining, 

hardmetals are exposed to high loads and temperatures. 

Depending on the material being machined, the manufacturing 

process used and the applied process parameters, temperatures 

of between 600 ° – 1000 ° C are reached. To understand 

the materials’ deformation behavior during machining, 

MCL performed experiments under monotonically increasing 

and cyclic loads, as well as creep tests under constant 

load and elevated temperature. A servo-hydraulic testing 

machine with a vacuum chamber was used to test the hardmetal 

grades under uniaxial load and at temperatures between 

room temperature and 900 ° C, figure 3a). Changes in 

length during the test were measured without contact using 

a high-precision laser extensometer, figure 3b). The specimen 

was inductively heated to the desired temperature and the 

constancy of the temperature over the measuring length was 

ensured by the use of thermocouples. The specimens have an 

hourglass geometry to prevent buckling under compression. 

Figure 3c) shows a glowing sample at 800 ° C. The stress-strain 

curves, recorded under monotonically increasing compressive 

load, show that the stiffness of the two hardmetal grades 

decreases significantly with the temperature increase from 

room temperature up to 900 ° C, see figure 3d). 

Further, both grades exhibit similar deformation behavior 

at the respective temperatures. Cyclic tests under pure compressive, 

symmetrical tensile and compressive load as well as 

creep tests showed the same deformation behavior. 

Analyzing the microstructure and deformation behavior, 

the research company MCL was able to prove that the 

“upGrade” grade CT-GS20Y has the same properties as the 

premium hardmetal grade CTS20D under the same loads 

and at elevated temperatures. This confirmed that the two 

hardmetal grades are equivalent in terms of these mechanical 

figure 3 

a) servo-hydraulic testing machine with vacuum chamber 

at the MCL; b) view into the vacuum chamber with mounted 

hardmetal specimen; c) glowing specimen at 800 ° C; d) stressstrain 

curves of CTS20D and CT-GS20Y at room temperature, 

200 ° C, 400 ° C, 600 ° C, 700 ° C, 800 ° C and 900 ° C 

under monotonically increasing compressive load 

loads and that high-quality secondary raw materials have no 

measurable influence on the mechanical and creep properties 

under extreme mechanical and thermal loads. Ceratizit’s 

customers therefore benefit from higher price stability and 

security of supply, as 99 % high-quality secondary raw materials 

are used in the production of CT-GS20Y, which also 

protects the environment and our climate. 

GrindingHub 2024, hall 9, booth C11 

further information: www.ceratizit.com 


17

news & facts 

KAPP NILES bids farewell to managing director 

Helmut Nüssle 

After more than 20 years with the KAPP NILES Group, 

Helmut Nüssle has taken his well-deserved retirement. The Group 

would like to express its sincere thanks for his many years of loyalty, 

his valuable and fruitful work and his extraordinary commitment. 

Helmut Nüssle joined the Group in July 2003. As interim manager, his task 

was to steer the company on a stable course. His successes ultimately led to 

his appointment as managing director in April 2004, where he was mostly 

responsible for controlling/ finance/accounting, human resources, sales and 

service/tools, as well as looking after the foreign locations. 

Since 2021 he has formed the management board of KAPP NILES together 

with Matthias Kapp, Michael Kapp and Michael Bär. During this time 

Helmut Nüssle was able to pass on his many years of experience and expertise 

to the current management team. 

He played a key role in shaping the Group through the introduction of 

a business management system with ongoing reporting, the professional 

manoeuvring of the Group through the various economic crises of recent 

years and, not least, the expansion of the company’s presence and success in 

Asia – particularly in China. 

Thanks to his many years of voluntary work, Helmut Nüssle was able to 

represent the interests of KAPP NILES to the world in the best possible way 

and provide further impetus for the company. 

Among other things, he was active in the legal 

and tax committee and the economic committee 

of the German Machine Tool Builders’ 

Association and in the Foreign Trade Committee 

of the Coburg Chamber of Industry and 

Commerce. 

further information: www.kapp-niles.com 

Federico Costa is the new president 

of ECTA 

For the next four years ECTA, the European Cutting Tools Association, 

will be led by an Italian president, Federico Costa, managing director 

of FEBAMETAL, based in Grugliasco (Turino), associate member 

company of UCIMU-SISTEMI PER PRODURRE, specialized on 

the production and sales of standard and special tools. 

The Turinese entrepreneur, elected in November 2023, has picked up the baton 

from Marcus Horn of the German company Paul Horn GmbH. 

Federico Costa stated: “The European tool manufacturers are currently 

operating in a context affected by international geopolitical uncertainty. This 

is added to the complexity introduced by the new regulatory requirements 

imposed by the European Union, which is certainly a challenge for our companies. 

The commitment of ECTA for the coming years will thus be to provide 

companies with food for thought and insight, as well as opportunities 

for exchanging views, to better move forward in this scenario. The annual 

events and meetings, which traditionally accompany the activity of ECTA, 

will indeed be focused on the issues of greatest interest to the European 

operators in this sector.” 

“As president of ECTA” added Federico Costa “I will work to improve the 

image of the European industry of the sector by proposing initiatives that 

can also help to durably strengthen its positioning in the international 

scenario. After participating in the next world conference on cutting tools, 

scheduled to take place in Osaka in the 

current year, the association, with the support 

of UCIMU, will be engaged in organising the 

ECTA conference to be held in Italy in 2025.” 

Members of ECTA, in addition to UCIMU- 

SISTEMI PER PRODURRE, are VDMA 

(Germany), AFM (Spain), SWISSMEM 

(Switzerland) and BHECT-MTA (Great 

Britain), joined by Further Sutton Tools 

(The Netherlands), ATA Tools (Ireland) and 

Boehlerit (Austria). 

further information: www.ecta-tools.org 


news & facts 

ModuleWorks and DN Solutions team to advance 

machine tool software development 

ModuleWorks, the leading software provider for the 

CAD/CAM industry, announces a partnership with 

DN Solutions, a prominent CNC machine tool builder, 

involving equity investment and business cooperation. 

This collaboration will foster a close working relationship 

between the two companies, focusing on the joint development 

of machine tools software and the creation of integrated 

solutions to drive the digital transformation of the manufacturing 

industry. 

DN Solutions leverages the specialized software development 

resources provided by ModuleWorks to enhance the 

pace of developing intelligent, highly automated machining 

cycles and user-assisted solutions within its diverse range 

of machining applications. It also represents a commitment 

from both companies to drive digitalization in the manufacturing 

industry. 

About the ModuleWorks strategic partner program 

The Strategic Partner Program initiated by ModuleWorks represents 

a commitment to advancing the development of intelligent, 

integrated manufacturing solutions through collaborative 

innovation 

between 

ModuleWorks 

and machine tool 

builders, CNC 

con trol manufacturers 

and 

CAM software 

vendors. In joining 

the Module- 

Works Strategic 

Partner Program, 

companies acquire a minority share in ModuleWorks. This 

financial investment enables ModuleWorks to provide its 

partners with dedicated software development resources 

and work in close cooperation with them to rapidly develop 

integrated solutions that drive the digital transformation in 

manufacturing. 

ModuleWorks Strategic Partners: AutoDesk, DMG Mori, 

DN Solutions, Mitsubishi Electric, PTC. 

further information: www.moduleworks.com 

Shrink fit tooling and machine technology 

Platinum Tooling, the importer and master distributor 

of live tools, angle heads, Swiss machine products, 

knurling and marking tools manufactured by various 

international suppliers, is now the importer of Rineck 

shrink fit tooling and shrink fit machine technology in 

the United States and Mexico. 

Established in 1966, Rineck started as a job shop for small 

parts, then became a producer of hydraulic parts for the mining 

industry and is now a globally recognized manufacturer 

of tool holding technology. Rineck’s investment in state-ofthe-art 

manufacturing equipment and commitment to innovation, 

research and development allows them to constantly 

look for ways to achieve the optimal balance of quality, consistency 

and affordability. 

Rineck offers standard and custom shrink fit tool holders 

with various connections including CAT, HSK, BT, SK, PSC 

and straight shank extensions. In addition, ER shrink fit 

collets are available. For added rigidity, flange or dual contact 

holders are available for CAT and BT tapers. A clamping 

range from 3 mm to 32 mm is possible for both slim and 

standard styles. All tools are available in inch and metric 

sizes. 

Rineck produces a wide range of standard shrink fit tool 

holders as well as custom tooling. In addition to standard 

4.5 ° taper tools, 3 ° slim 

and extra slim tools are 

available. Most holders 

come standard with 

length adjusting screws. 

Coolant delivery to the 

cutting tool can be 

achieved either through 

the center or flange of 

the tool holder utilizing 

coolant jets or slots. 

In addition to shrink 

fit tool holders, Platinum 

Tooling will offer shrink 

fit machine technology. 

Equipped with an ele vation cooling system, heated tools 

can be moved to a cooling tank with a push of a button. The 

machine’s smart design keeps accessories stored but close at 

hand during operation. 

For this new line of shrink fit tooling and machine technology, 

Platinum Tooling will handle application engineering, 

sales and service through a network of distributors across the 

United States and Mexico. 

further information: www.platinumtooling.com 


19

news & facts 

A half-century contribution to industrial progress 

through precision cutting tools 

Family, fulfillment, and a fascination with technology 

are all part of a formula that has seen ANCA lead the 

demanding niche of CNC tool and cutter grinders for 

a half-century. 

In its time, the Australia-based global business has 

made an enormous yet largely hidden contribution to 

the world, selling over 10,000 5-axis CNC machines 

to over 2,500 customers. Around 1.1 billion tools have 

been created using ANCA’s grinders. 

“You would be very unlikely to find any bit of advanced equipment, 

anywhere in the world, that hasn’t been touched by a 

cutting tool which has been manufactured on one of our machines,” 

explains co-founder Pat Boland, whose company’s 

customers include Boeing, Rolls-Royce, Iscar, Sandvik, Sutton 

Tools and many other household names. 

The two Pats 

Boland and Pat McCluskey – then an electrical engineer and 

an industrial electronics tradesman – met at a governmentowned 

munitions factory in Melbourne in 1968. The two Pats 

started ANCA in 1974 in a spare room at Boland and wife 

Libby’s home. 

“It wasn’t about money in the beginning, and for me it’s 

not about money now… I get my kicks out of designing new 

machines,” explains McCluskey. “Even before we started 

ANCA, Pat and I have always been driven by simply wanting 

to get machines to do things better. My enduring philosophy 

in business is if you always do what you’ve always done, 

you’ll always get what you’ve always gotten. New ideas and 

new thinking are the basis of our business.” 

ANCA’s highly sophisticated CNC grinding machines are 

exported around the world, with 98 % of its revenue being generated 

by exports. The ANCA Group also makes associated 

The two founders, Pat McCluskey and Pat Boland 

The Boland family 

equipment and software, including robot arms, software, and 

control systems, and offers automation services and technology 

to OEM machine builders. 

Leading the incredibly demanding tool and cutter market – 

where nanometer-level details matter – means a reinvestment 

of roughly a tenth of revenues back into R&D. 

A near-obsession with solving customer problems has seen 

ANCA contribute a collection of world firsts to its industry, 

including the first probe for digitizing tools, first modem for 

support and diagnostics in a machine, first full and true 3D 

simulation of the grinding process and many more. 

Martin U. Ripple, who has been at the helm of ANCA as 

CEO since November 2022, reflects on the company’s enduring 

legacy. “In all my interactions, I’ve observed a consistent 

thread – our customers invariably share fond recollections of 

their encounters with ANCA dating back to the 70’s, 80’s and 

90’s. It’s evident that there’s a deep-seated loyalty and trust 

towards our brand”, he notes. 

Ripple, always keen on uncovering the unique elements 

that set a business apart, asks, “what is the secret ingredient 

that differentiates us from our competitors? What makes 

ANCA exceptional?” His answer is the involvement of family 

in the business, a fervent passion driving the company forward, 

and a steadfast commitment to providing customers 

with the most innovative products. This blend, according to 

Ripple, is the essence of ANCA’s success and longevity." 

A sharp focus on both vertical integration 

Edmund Boland, son of Pat and ANCA CNC Machines’ general 

manager, values ANCA’s agility as a privately owned 

company which enables swift decisions to support ANCA’s 

people and customers. “ANCA has always endeavored to stay 

ahead of the curve, anticipating market trends and delivering 

cutting-edge solutions which enable our customers to thrive. 

With 50 years of innovation behind us, our product and 


news & facts 

technology portfolios are perfectly placed to meet the challenges 

of the future.” The delivery of technical and practical 

excellence has required a sharp focus on both vertical integration 

– creating everything from the machines’ motors to 

their polymer concrete bases to their sheetmetal canopies – 

and both trade and university-taught skillsets. 

ANCA has trained more than 60 apprentices and established 

its formal apprenticeship program in 2011. McCluskey 

enthusiastically wrote the course material for this. While 

being very particular with skill and technology development 

is one way to look at ANCA’s story, Pat Boland also likes to 

zoom out to a very general view. 

The ANCA era runs 50 years and counting, touching 

countless lives, operating in the background. It’s shorter 

than, but has similarities to the overall story of toolmaking: 

critical to industrial progress, even if it needs pointing out 

every now and then. “For the vast sweep of history, the only 

evidence of homosapiens and our predecessors are cutting 

tools,” says Boland. 

“And a number of the broad eras of human life are really 

named after cutting tools. So the stone age, the bronze age, 

the iron age. What we’re talking about is the technology of 

cutting tools as much as anything.” 

Celebrating a golden achievement across the globe 

To mark the occasion of ANCA’s 50 th anniversary, the 

company is hosting a series of open houses, seminars, events 

and attending tradeshows worldwide. As innovation has 

motivated ANCA throughout the company’s history, new 

products and developments will be at the center of the 50 th 

year celebrations. 

At global tradeshows and ANCA Open House events, precision 

manufacturers can experience new hard- and software 

for micro tool and gear tool manufacturing, edge preparation, 

closed loop manufacturing and automation. 

Russell Riddiford says: “Our large and experienced group 

of engineers and developers is continuously presenting new 

solutions to meet customers’ needs. Highest quality tools 

and lowest cost per part are the guiding principles leading 

to groundbreaking, real-world innovations. Examples 

are our new MicroX CNC grinding machine, using nanometer 

control technology and ANCA Machine Intelligence 

to produce micro tools of unseen quality, or our AIMS system, 

the world’s first and only autonomous system for tool 

manufacturing." 

further information: www.anca.com 

A new technology center in Korea 

ANCA is thrilled to announce the grand opening of its 

new state-of-the-art technology center in Korea. 

ANCA has offered local sales and service to customers across 

diverse industries for more than 30 years in the Korean market 

and opening the new facility is a significant milestone for 

the company as it expands its presence in the Asian market. 

Jake Farragher, general manager of ANCA Asia, says, 

“ANCA’s newest technology center is a commitment to our 

customers in Korea. This investment in our global infrastructure 

enables our team to deliver premium sales and 

service support to this important and growing market. We 

understand the importance of offering customers local support 

and at our new facility we can showcase the capability of 

our flexible grinding machines, world-leading software, and 

market-first automation solutions.” 

FX7 ULTRA and MX7 ULTRA 

For 50 years ANCA has committed to providing cuttingedge 

grinding solutions worldwide, and ANCA Korea, located 

near Seoul, is equipped with the latest technologies, such 

as ANCA’s ULTRA technology with nanometer resolution 

control. 

The demonstration facility provides the ULTRA experience 

with ANCA’s MX and FX ULTRA machines, as well as 

automation solutions with ANCA’s Integrated Manufacturing 

System (AIMS). The facility additionally includes support 

and training services. 

The grand opening event was attended by key stakeholders 

and customers, industry partners, and local dignitaries. 

Opening ceremony of the new technology center near Seoul 



21

news & facts 

LACH DIAMANT – 100 Years 

Tradition. Passion. Innovation. 

part 9: 

Luck and success in the years of decisions – 

new beginnings 

“When I held my first diamond in my hand in 1908, I would not have 

imagined that one day diamonds would not only be used in the automobile 

industry but also for the machining of wood and plastics”. 

Jakob Lach, the company founder, said this on camera in 1980. It 

would become the preface for the first presentation of a new technique 

for machining wood and plastics – using diamonds as cutting 

material – the Dia Tool. This video, with audio translated into multiple 

languages, has lost none of its relevance for the choice of appropriate 

tools within the furniture, flooring and composite industries; the 

video can be viewed at: https://bit.ly/LACHDIAMANT 

It happened on a day in January, 1981; 

the phone call came as a surprise 

and unexpectedly … 

By now, the LACH DIAMANT company – Jakob Lach GmbH & Co. KG in 

Hanau am Main – was comprised of four production facilities. 

Hanau, Ameliastrasse, the newly founded LACH-SPEZIAL-WERKZEUGE 

GMBH for the production of diamond/PCD tools for cutting wood, plastic, 

and composite materials (GRP, CFRP) for the furniture and flooring industry, 

aircraft industry and circuit board manufacturing industry. 

Hanau, Fasanerieweg, the LACH DIAMANT production of resin and metal 

bond diamond and CBN grinding wheels for the grinding of carbide, hardened 

steel, ceramics, and glass. 

Hanau, Bruchköbeler Landstrasse 39, with the grinding shop division for the 

production and service of natural diamond turning tools, profile and copy diamonds, 

as well as single-point dressing diamonds for the dressing of traditional 

grinding wheels, and – in the new building no. 41 – the production and 

service of dreborid PCD cutting tools for the turning and milling of aluminum 

and other non-ferrous materials, graphite, and green ceramics, as well as 

hardened steel. 

Every day logistics and communication had to be mastered, with corresponding 

effort and expense, by sales, production planning and shipping. The 

accounting and finance department were housed in additional containers. 

In other words it had become quite crowded. No wonder, the successful expansion 

of all LACH enterprises demanded its price. 

Day by day, the production team was confronted with new ideas to expand 

applications for polycrystalline tools, to cut costs, to multiply tool lives, and 

thereby to render possible new products and designs. 

For example, so far profile/thread turning tools had to be polished in a timeconsuming 

manner on profile grinding machines, but now eroding made this 

process fast and easy. 

Company founder Jakob Lach, 1894-1984 

(photo taken in 1980) 

Or, the newly developed, and patent-pending 

diamond dressing roll drebojet®, featuring a 

new technology for “milling instead of dressing” 

of traditional grinding wheels with drebojet® 

PCD mill-dressing rolls (later European patent 

no. 0038929). 

In short, and this was clear to all of us: 

it could not go on like this. We had to find a 

solution for the future, and build new. 

…so, I picked up the phone 

Mr. Schmitz (name changed) from Wiesbaden 

was on the line, introducing himself as a business 

consultant for Israeli companies. He 

represented a small start-up company from 

the Sea of Galilee, interested in know-how 

for the production of electro-plated diamond 

needle files. 

“As a manufacturer of diamond tools, you 

can surely help me”, he said. At first, I was 

surprised, and answered: “Why of all things, 

know-how for diamond needle files? Worldwide 

many people are dealing with this product”, 

and after a little pause I added “LACH or 

LACH DIAMANT has something better for 

this start-up company.” “What would that be?” 

came the next question, as expected. “Unfortunately, 

I cannot reveal this just yet, the 

product patent is still pending…” 

This is how the first conversation proceeded, 

back and forth, and it continued like that in 

the following conversations with the now curious 

start-up company and its investors. 


news & facts 

drebojet® drebobloc® drebojet® 

Successful conclusion 

To make a long story short: a few weeks later, on March 30 th , 

1981, we met again at a Frankfurt notary in order to finalize a 

multi-million know-how and license contract, including the 

required eroding machines (with LACH EDG technology) 

for the manufacturing of polycrystalline (PCD), wood and 

plastic cutting tools. 

Both parties were satisfied. Our contract partner’s trust in 

LACH DIAMANT was not disappointed. And we could start 

our new building project faster, due to better framework conditions. 

After a short search a large, undeveloped major property 

was found at Donaustrasse in Hanau. This was the one, 

and most successful, single transaction of the year 1981. 

All in all, three trade shows were at the center of our 

attention, all attended by LACH DIAMANT and now also by 

LACH-SPEZIAL. First of all, FAMETA in Essen. For the first 

time, we had a live demonstration of a PCD cutter for aluminum 

profiling on a Hermle tool milling machine. 

After the world premiere of diamond tools at LIGNA 1979, 

LACH-SPEZIAL exhibited a second time at this trade show 

and presented the new diamond technology to a fascinated 

industry. 

All this even though some competitors warned against 

using the PCD cutting edges which were soldered onto the 

base body. Allegedly the PCD cutting edges would come 

lose during milling and endanger both man and machine. 

Dieter Claus, our chief engineer, felt compelled to initiate 

an inspection at the test center of the German Trade 

Association for wood machining tools, even before the start 

of LIGNA. The inspection certificates (BG Test and BG 

Form) clearly confirmed the tool quality and safe use of our 

diamond tools. 

FAMETA 1980: this was left of the 

original aluminum block at the end of the trade show 

Quasi-world premier at FAMETA 1980: milling of an 

aluminum profile with a PCD monoblock milling cutter; 

the photo shows young Robert Lach, now CEO and director, 

capturing the milling process on the first monoblock milling 

cutter for aluminum with a super 8 camera 


23

news & facts 

European patent for drebojet® mill-dressing rolls, 

registered for patent in 1981 

Present at trade shows 

At this trade show, LACH-SPEZIAL presented 

diamond end mills with axial angle cutting 

edges as a world novelty; this progress had 

been made possible by the further advancement 

of the LACH sharpening technology. 

Worldwide the continued success of LACH- 

SPEZIAL-WERKZEUGE was noted in technical 

press publications, including in the USA. 

Among other highlights, EMO 1981 in 

Hanover featured advanced CBN Borazon 

grinding wheels for tool grinding, featuring 

the “tressex® bond” with its superior feed performance. 

At EMO ’81 LACH DIAMANT presents the 

new CBN tressex 8000 tool grinding wheel with 

maximal performance 

Test certificate BG-FORM and BG-TEST; after examination, a diamond profile 

milling cutter was marked “BG-FORM” back then – today “BG-TEST” 

A trade show report in MM-Maschinenmarkt 87/1981 was especially 

interesting to me. Besides reporting on LACH diamond cutting edges, 

attached directly to the base body, the article mentioned “regarding traditional, 

clamped cutting edges… another option is to solder the PCD blanks 

directly into the milling body. A comprehensive portfolio of such tools was 

presented by Jakob Lach GmbH, Hanau … “. 

This is especially noteworthy because monoblock compact milling tools 

were introduced as novelties at trade shows in the 1990’s; this also was preceded 

by the development of soldered diamond milling tools for cutting 

wood and plastics, respectively composite materials. 

What the press wrote 

What made me especially happy, was the great interest in our drebojet® milldressing 

rolls for the dressing of traditional grinding wheels, first pre sented 

at EMO. I quote from a first 

mention as state of the art 

technology in the magazine 

“Fachberichte für Metallbearbeitung” 

(Technical Reports 

for Metal Machining), issue 

11-12/1981: “EMO ’81 – world 

LIGNA 1981: presentation of the 

first axial angle PCD end mill 

novelty – drebojet® diamond 

mill-dressing roll – the new 

tech nology for diamond profile 

dressing of grinding wheels 

in series production: LACH 

DIAMANT – Europe’s no. 1 

in processing polycrystalline 

synthetic diamonds – presented 

at EMO ’81, partnering 

with Abawerk GmbH, 

Aschaffenburg, the world novelty 

drebojet® for profile milldressing 

of grinding wheels in 

series production. 


news & facts 

Among other interested licence holders 

the Japanese diamond tool manufacturer 

Asahi Diamond also contacted us. The following 

negotiations with Arihisa Tanaka, president 

of Asahi Diamond, were accompanied 

by Mr. Kato, our patent attorney in Tokyo; 

thanks to his legal assistance both a licence 

and a know-how contract were drafted which 

allowed the use and production of a PCDtipped 

diamond mill-dressing roll according 

to LACH patents. On March 23 rd , 1982, both 

contracts were approved by president Arihisa 

Tanaka and Horst Lach. 

The time is now 

After licence and know-how sales to Israel 

and Japan – both being extremely successful 

business deals – we asked ourselves when to 

reunite all our outsourced business units? 

Diamond monoblock milling cutter with soldered PCD cutting edges – 

a view into a future with even more cutting edges – example Z = 16 with 

cool injection and chip breaker for aluminum machining 

in series production. 

Traditional diamond dressing rolls, tipped with natural or synthetic diamonds, 

manufactured according to different procedures, in a number of different 

precision levels; however, they all have one thing in common: independent 

of geometries, their form is always closed, not interrupted. This is 

different for drebojet®, dressing becomes a milling process. For this reason 

LACH DIAMANT calls drebojet® a diamond mill-dressing roll. 

Polycrystalline synthetic diamonds, proven superior to all other hard 

materials in all areas of machining – turning, milling, shaping, drilling – of 

aluminum, plastics, and even wood and stone, reinforced this new dressing 

technology. 

All requirements for this great project had 

been met. Both companies, Jakob Lach GmbH 

& Co. KG and especially LACH-SPEZIAL- 

WERKZEUGE GMBH, up-and-coming due 

to the rapid development and spread of diamond 

tools for all wood and composite materials, 

were at stand by with their resources. 

We were able to acquire a yet undeveloped 

property with 24,000 m 2 in the new industrial 

area in North Hanau. The first phase of construction 

included a large hall for the natural 

diamond grinding shop, plus a production facility 

for polycrystalline diamond and CBN 

tools as well as for the production of dia mond 

and CBN grinding wheels – including a big 

Much like during milling, the “chip chambers” between the single teeth 

allow for a maximal cut into the grinding wheel, and therefore provide an 

excellent chip removal. 

The excellent performance of the drebojet® mill-dressing roll during the 

dressing procedure is clearly shown by a subsequent visual inspection of 

the grinding wheel dressed/profiled in such a way: the milled abrasive bodies 

stay absolutely stable for the next grinding process (i.e. are not crushed), 

unlike with traditional dressing methods. 

The result is equally shown by an extended interval from one dressing to 

the next; the grinding wheel’s operating time is prolonged. A polycrystalline 

diamond cutting edge offers yet another technological novelty: by adjusting 

the cutting speed of the diamond mill-dressing roll, it is possible to 

determine the actual surface roughness of the drebojet®-dressed grinding 

wheel. 

Installing automatic controls in future drebojet® dressing processes will 

maximize the dressing efficiency in series dressing of grinding wheels. Even 

international technical publications covered this novelty with enthusiasm. 

Understandably, our competitors and other manufacturers of diamond 

rolls took note of this new technology, first introduced by LACH DIAMANT 

and now patented. 

drebojet® PCD mill-dressing roll, tipped 

with profiled cutting edges, in action 


25

news & facts 

The Asahi Diamond team after completing a training as 

part of the know-how transfer – in the middle 

Horst Lach, on the right side Dieter Claus. 

Our very own Ms. Stein-Junkuhn – after a dragon boat race 

of the “Diamond Dragon”, Hanau 2013, 

once again with the right beat to a team win 

cafeteria with a kitchen. A stand-alone administrative building 

for sales and accounting, both bursting at the seams at 

their current location, was to follow shortly thereafter. Inauguration 

and move-in were planned for the spring of 1984. 

Development work pays off 

I do not necessarily want to call it a “gold rush” spirit that had 

seized us during the years from 1981 to 1982; however this expression 

captures the atmosphere quite well. All of us, including 

the sales employees outside, were caught by this “motivational 

wave”. Our versatile development work of the last decade 

payed off. It had an exemplary start in 1969 with the production 

of (Borazon®) CBN grinding wheels; followed by the 

first presentation of PCD dreborid® cutting tools in 1973, and 

the subsequent introduction of polycrystalline dreborid®-G 

CBN tools in 1974/75. In 1977 another premiere presentation 

of rotating PCD tools, e.g. mills for edge cutting, scorers 

and saws for fiberglass materials used in the production 

of circuit boards, and of course in 1979, after the discovery 

of spark erosion (e.g. LACH EDG procedure) it lead to a sort 

of “industrial revolution” in the mass producing wood and 

furniture industry, as well as in the aluminum-processing 

automobile industry and its suppliers. From today’s perspective 

(2024) it would have even further implications. In short, 

the “LACH companies” were prospering. 

New employees were hired. New ideas and thoughts could 

be entertained and developed further. The success of the 

licence and know-how sales had somehow created a specialized 

new sales department; immediately, we became more 

international. Requests from abroad multiplied. There was 

an interest in external representation. Negotiations had to be 

conducted. 

“LACH Diamant, executive secretariat, 

Stein-Junkuhn” 

The project “new building Donaustrasse” demanded full attention, 

besides the increasing tool business. Help came on 

January 2 nd , 1982, in the person of a young woman named 

Rita Stein-Junkuhn. Her work place – at that time still in the 

administrative section at Bruchköbeler Landstrasse – was 

equipped with the latest automated writing device called 

“Teletex”. For the first time it was possible to digitally send 

texts and letters with “Teletex”, provided the recipient had a 

compatible device. Originally “Teletex” was meant to replace 

the so-called tele typewriter (with perforated tape), but then 

the “Teletex” service was discontinued at the beginning of 

the 1990’s. Afterwards fax machines and the emerging data 

technology, meaning computers, were to dominate daily office 

routines more and more. 

With “Teletex” as instant communication device or via 

serial letters we could now get in contact with interested 

licence and know-how prospects all over the world. 

The executive secretariat under Ms. Stein-Junkuhn became 

an institution of its own at LACH until she retired after over 

40 years as my personal assistant. 

Yes, now the international business really got started. The 

next milestone achievement for the further development of 

LACH DIAMANT 

enterprises up to the 

100-year anniversary 

in 2022, had something 

to do with an 

advertisement in 

“THE WALL STREET 

JOURNAL” on July 

15 th , 1982. 

More on this in the 

next article – part 10 

of “100 Years LACH 

DIAMANT” by 

Horst Lach 

further information: 

www.lach-diamond.com 

Advertisement in 

THE WALL STREET JOURNAL 


GrindingHub 2024 shining the spotlight on 

grinding technology 

news & facts 

Uli Regenscheit 

GrindingHub is set to open its doors for the second 

time to grinding experts from all over the world May 

14 - 17, 2024. The event will show more than just technical 

products and innovations, as Dr. Markus Heering, 

managing director of the organizer VDW (German 

Machine Tool Builders’ Association), reports. 

The trade fair concept expands the tried and tested elements 

but also breaks new ground. The latest trend topics are presented 

in the GrindingSolutionPark Science and in the 

Startup Hub: the overall concept establishes close links 

between business and research. It is important to include 

smaller companies and start-ups in the industry get-together. 

This is why the Startup Hub was created, offering ideal conditions 

for innovative companies. For the first time there 

will also be a joint stand for Swiss companies. This market 

is particularly important for grinding technology, and its 

exhibitors will now have the opportunity to get a taste of the 

GrindingHub and present their products and services to the 

visitors under their national banner. 

A further focal point will be on digitalization in production. 

This includes a further live demonstration of umati, the 

joint interoperability initiative of the VDW and VDMA for 

global data connectivity. Numerous exhibitors will be connected 

to the umati dashboard and will be recognizable by 

the distinctive sticker on their machines. 

The supporting program is rounded off by the Specialist 

Forum (Fachforum) in hall 10, booth E80, which will provide 

a platform for exhibitor of all kinds of presentations. Companies 

will be giving live, 20 min. presentations, informing 

the audience first-hand of what’s new in the world of grinding 

technology. 

GrindingHub 2024 in figures 

A total of 487 exhibitors have registered, making it necessary 

to open a fourth hall. Visitors can look forward not only 

to an increased number of companies, but also to greater 

diversity in terms of international involvement. The exhibitors 

will be coming from a total of 31 countries – eight more 

than last time. With the largest contingents coming from 

Germany, Switzerland, China, Italy and Japan. Accordingly 

the VDW is expecting an increased number of visitors from 

Asia now that the coronavirus-related restrictions have gone. 

The exhibitors are spread across 40 sectors, from grinding, 

polishing and honing equipment through to cylindrical 

and non-cylindrical grinding machines, cooling and lubrication. 

In the grinding, polishing and honing products segment 

the organizers have registered almost 120 % growth. The top 

5 sectors include cylindrical and non-cylindrical grinding 

machines, grinding machines for the cutting and machining 

of tools, machines for lapping, polishing and honing as well 

as surface grinding machines. 

Grinding technology as a crucial component 

in the global manufacturing industry 

Grinding is a key metalworking process that comes at the 

end of almost every process chain, ensuring a precise surface 

finish and dimensional accuracy. Accordingly grinding technology 

plays a decisive role in determining the durability 

and functionality of a wide range of end products. Grinding 

technology is also particularly important for energy efficiency 

as a result of lower energy losses and for environmental 

friendliness due to the reduced emissions. 

The total volume of global machine tool production 

amounted to 80.4 billion Euro in 2022. Grinding technology 

accounted for about 7 % in this, 5.5 billion Euro. The production 

volume has thus increased by 14.9 % compared to 2021, 

although the share has remained almost the same. 

“At GrindingHub 2024 trade visitors will once again be able 

to experience the entire world of grinding technology live 

and first hand. The trade fair reflects the internationality and 

diversity of the industry and thus offers an excellent opportunity 

to forge contacts across national borders and opening 

into new markets”, summarizes Dr. Markus Heering. 

further information: www.grindinghub.de 


27

processes 

Technology – tool – digitization 

Surface finishes – fine and polish grinding 

You can meet the requirements for the highest surface 

qualities economically and reproducibly with 

fine or polishing grinding on KAPP NILES machines. 

Combined tools with different specifications are used 

for this purpose. 

Conventional generating grinding uses a ceramic-bonded 

corundum grinding worm that consists of one specification 

throughout. 

Fine grinding uses a combined tool with two specifications. 

In addition to the conventional grinding area, the tool has a 

fine grinding area that differs in terms of the tool specification. 

This allows surface finishes of Rz = 1 – 2.5 micrometer 

to be achieved with process reliability. 

For even higher requirements conventional grinding is 

combined with polish grinding. For this process a tool with 

two areas is used. For polish grinding a tool area with an 

elastic polyurethane or synthetic resin bond is used. Surface 

qualities of Rz < 1 micrometer can be achieved. 

After hardening gears are conventionally ground to remove 

the existing allowance including hardening distortions and 

to produce the final workpiece geometry. The tooth flanks are 

then shot-peened to harden the surface. In the final work step 

they are polish-grounded with a one-piece polyurethanebonded 

tool as a single technology to achieve a high surface 

quality. 

With the demands for higher flank load capacity of gears 

and efficiency increases of gear boxes, fine and polish grinding 

has become more and more established in recent years, especially 

for applications in the passenger car and commercial 

vehicle sector. By integrating these downstream processes, 

surface finishes of Rz < 1 micrometer or Ra < 0.2 micrometer 

can be achieved on conventional gear grinding machines. 

Tools – dressing tools 

KAPP NILES manufactures diamond profile rolls as well as 

diamond form rolls for generating grinding with ceramicbonded 

worms. In large-scale production the dressing of the 

worms can also be carried out with highly productive multiribbed 

diamond profile rolls. For profile grinding, diamond 

form rolls in sintered design are offered for profiling dressable 

profile grinding wheels. Diamond dressing gears for profiling 

dressable honing rings complete the portfolio. 

Profile grinding – diamond form rolls 

Diamond form rolls are available in sintered design for profiling 

dressable profile grinding wheels. In addition to the 

economic version with natural diamond, these are also 

Dressing tool collage 4form rolls 

offered as a long-life tool with handset CVD diamond. It is 

possible to reground these tools several times and they are 

characterized by a long life time. 

Generating grinding 

Diamond profile rolls, diamond form rolls and 

multi-ribbed diamond profile rolls 

The portfolio includes workpiece-specific dressing rolls for 

dressing of ceramic-bonded worms as well as dressing rolls 

for flexible or topological dressing. The dressing tools are 

used for generating grinding with natural entanglement 

and topological generating grinding with influenceable bias. 

Multi-ribbed diamond profile rolls are also available for fast 

and efficient dressing. They are produced in galvanically negative 

design for a wide range of modules and rib numbers. 

For serial production, an integrated tip dresser is used for defined 

grinding of the gear root area. Dressing rolls without 

tip dresser are also part of our portfolio. 

Dressing tool collage profile rolls 60 cm 

with x6multi-ribbed roll 

The dressing tools for fine and polishing grinding – used 

in electromobility – are high-precision designed. The special 

feature of such a dressing roll is, in addition to the reference 

surface optimization, the reworking of the diamond grains 

after the coating of the dressing roll base body. 


processes 

Dressing tool collage dressing gears 

Grinding tool collage CBN worms 

Gear honing 

Diamond dressing gears 

Diamond dressing gears are offered for profiling dressable 

honing rings. This type of tool is also available as a tool set 

consisting of dressing gear and integrated tip dressing roll to 

move back the tip of the tooth at the honing ring. 

Highlights 

➢ worldwide replating close to 

the customer 

➢ application-specific design and 

manufacturing 

➢ maximum level of quality and 

several decades of experience 

KAPP NILES manufactures non-dressable, electroplated 

single-layer CBN tools for hard and soft finishing of gears 

and profiles. Their tools have been among the top products 

worldwide since decades. They are used when the highest 

demands are made on quality, performance and economy. 

CBN profile grinding wheels 

CBN profile grinding wheels are available in single or 

multi-ribbed roughing and finishing design and are used for 

grinding of: 

➢ external and internal gears in automotive (passenger 

car, commercial vehicle) and aircraft industry 

➢ radial, screw, rotor and worm profile wheels 

➢ 

➢ 

Grinding tool collage CBN_wheels 

high speed grinding of profiles and gears 

plunge grinding, abrasive cutting and 

cylindrical grinding 

CBN grinding worms 

CBN grinding worms are available in roughing and finishing 

design. They are used as cylindrical grinding worms for 

highly productive grinding of external gears and other profiles. 

Grinding worms and profile grinding wheels are often 

used in combination. 

Digital solutions 

Perfect interaction for efficient processes 

Digital solutions from KAPP NILES are displayed in the 

software platform KN assist. These digital products aim to 

generate the greatest possible added value. Quality, availability, 

efficiency, resources, user-friendliness and service play a 

major role here. The focus is on the core areas of connectivity, 

production and support in order to master all current and future 

challenges together with the customer. The digital solutions 

thus stand for a perfect interaction of efficient processes 

around the machines. 

Highlights 

➢ reduction of reject rates through 100 % 

real time monitoring of components 

➢ early detection of defects 

≥ rejection of conspicuous components 

in time 

➢ process monitoring can be adapted to 

the customers requirements 

Process monitoring can be defined as component-specific 

monitoring and evaluation of the grinding and dressing 

process. It is possible to generate an action instruction 

from the sensor signals. Various characteristic values are 

formed from time signals, in the simplest case these can be 

maximum or RMS (Root-Mean-Square) values of the signals. 

The characteristic values are then combined with the 

known project data via algorithms and processed into indices, 

such as a noise or damage of grinding worm index. Process 

monitoring has interfaces to further functionalities 

(such as part tracing) and an export function for off-machine 

analysis. 

Transmissions in e-mobility do not only have to be efficient, 

but also quiet. Up to now workpieces with negative noise 

behaviour have usually been detected in EOL or in some 

cases on the roller test bench. The common random measurement 

of machined workpieces can only detect individual 

deviations, which later have an effect on the noise behavior 

of the gearbox. This is where the process monitoring developed 

by KAPP NILES comes into the picture. 


29

processes 

Condition monitoring from KAPP NILES makes it possible 

to monitor the condition of linear and rotary axes with 

regard to wear. The wear is determined by reference runs 

after workpiece machining and can be started manually or 

via a timer function. No retooling is necessary for this; the 

reference run is carried out independently of the tooling 

being set up. The condition is evaluated by means of indices, 

after which a prognosis is made about the durability of the 

axes. Once the wear condition has been transmitted as an 

index per axis, a visualization of the wear progression takes 

place via the HMI. Condition monitoring has interfaces to 

further functionalities (such as part tracing). 

Gears comparison conventional generating 

grinding-polish grinding 

Based on internal machine control signals and signals 

from specifically used acceleration sensors, characteristic 

values are formed to assess the grinding process. This makes 

it possible to identify workpieces with noticeable noise during 

machining effectively and cost-effectively. This reduces 

the amount of scrapped parts. 

In addition to noise anomalies other deviations can also 

be detected with the support of process monitoring so as to 

meet the high quality requirements in the field of e-mobility. 

The data obtained with process monitoring can be used, 

among other things, to establish a correlation between the 

processing machine and the transmission test bench or measuring 

machine. This makes it possible to derive further 

findings for process optimization. 

Condition monitoring 

Highlights 

➢ reduction of unplanned machine downtime 

➢ avoidance of unnecessary or premature replacement 

of components 

➢ maintaining production quality by monitoring 

quality-relevant components 

Digitisation remote service 

Digital service – remote service 

Highlights 

➢ faster and simpler support and solution finding 

through targeted communication via a ticket system 

(no e-mail traffic) 

➢ documentation, operating instructions and e-plans 

for each machine available digitally and up-to-date 

➢ transparent communication about the status 

of the service request 

With the remote service KAPP NILES provides its customers 

with a self-developed solution to ensure fast and efficient support 

in service cases. The use of modern communication 

technologies enables a targeted and effective solution finding. 

This remote service offers a wide range of functions to 

ensure the smooth processing of service requests. Customers 

can submit their requests in a structured and efficient 

manner via a ticket system. Support is provided through 

various communication channels such as live video, voice 

over IP, chat and whiteboard functions. This allows problems 

to be identified quickly and solutions to be communicated 

directly. 

Another advantage is the comprehensive documentation of 

service activities. Detailed documentation is created for each 

machine and stored in the system archive. This documentation 

enables quick access to the service history and ensures 

transparency and traceability. 

The status of the service request and the documentation 

can be called up in real time to create transparency. 

GrindingHub 2024, hall 7, booth A40 

KX 300 P fine grinding combined worm 

further information: www.kapp-niles.com 


processes 

Change– before you have to! 

Over the last few years Adelbert Haas has put a 

wide variety of turnkey solutions into operation. The 

basis for this is based on nothing less than the perfect 

interplay of hardware and software. The key words behind 

these turnkey solutions: highest productivity and 

flexibility with maximum precision. Turnkey grinding 

is no longer enough. 

With the Multigrind® Radical, Adelbert Haas is continuing 

this tradition and bringing the future of tool grinding to life at 

GrindingHub. A visit to the stand in hall 10 is well worthwhile. 

The core topic of the precision specialists: the end-to-end 

digitalization and automation of manufacturing processes. 

Adelbert Haas has some ground-breaking innovations at 

the start. First and foremost the Multigrind® Radical in fully 

automatic mode. Intelligent Automation 4.0: not a theoretical 

approach, but applied reality. With productivity that deserves 

the label quantum leap. Needs-based production simply directly 

from the web store via the ERP system to dispatch, 

without any major programming effort. The core element 

here is the Multigrind® Radical, which grinds high-precision 

tools in unmanned operation thanks to Closed Loop. Thanks 

to intelligent automation 21 shifts are completed every week, 

with minimal effort required for preparation and post-processing. 

The individual production steps are controlled by the 

Multigrind® Multimation software. Machine operation and 

machine control are possible at any time, from anywhere and 

from any device, because every Multigrind® Radical is always 

The Multigrind® Radical forms the heart of Automation 4.0 

online. Maintenance is carried out proactively based on the 

analysis of the machine data. As a result there are virtually no 

machine downtimes and non-productive times are so minimal 

that they are no longer relevant. 

The precision specialist from Trossingen will also demonstrate 

the performance results from the perfect interplay of 

hardware and software on its tried-and-tested all-rounders 

and problem solvers. Also on show: the Multigrind® CB and 

Multigrind® CA. The performance of the universal grinding 

machines will be demonstrated by the production of rotors, 

which will be ground live under oil at the trade fair stand in 

Stuttgart. GrindingHub 2024, hall 10, booth C50 

further information: www.multigrind.com 

The new era of clean-tech machining 

Disposal of used cutting fluids causes significant 

environmental contamination. Annual consumption 

of cutting fluids is estimated over 2 billion liters – although 

the actual amount is assumed to be up to 10 

times higher, as most fluids are diluted before their 

use. Cutting fluid treatment and their release to the environment 

leads to significant oxygen depletion and 

nutrient destruction in surface waters. 

Aurion technology 

The core of the Aurion technology is in the ionized air which 

generates an electrochemical process resulting in electron 

loss and atomic level transformation of Aurion gas medium 

at the cutting surface. The electrochemical process acts as a 

dry lubricant in the cutting process, penetrating the cutting 

zone and optimizing the interaction between the tool edge 

and the workpiece. This process accelerates oxide layer formation 

and significantly reduces the friction, thermal stress 

and tool wear. 

This system consists of three components – ionizer, controller 

and air-cooling unit, it is connected to the factory compressed 

air network and machinery CNC. Ionized air pressure remains 

at 2 - 3 bar and temperature in the -10 ° to + 10 ° C during machining 

operations. Its technical properties have been proven 

in thorough tests conducted by authoritative institutions and 

industrial partners. Most recently the respected Advanced 

Manufacturing Research Centre (AMRC) of the University of 

Sheffield achieved excellent results in titanium milling trials. 

Economically compelling solution 

Aurion reduces manufacturing costs and cutting lead times 

in workshop processes. Thousands of validation runs have 

proven that Aurion technology delivers at least the same machining 

quality and performance as cutting fluids – measured 

by cutting speed, tool life and surface quality. Ionized clean 

air is safe for its operators and the relevant machinery and 

meets the highest standards for workpiece residuals. 

Easy to use and integrate 

Suitable for all machining applications and materials, easy to 

integrate to existing and new machines, either by using the 

external piping to the cutting zone or by using existing coolant 

channels in standard toolholders and tools. 

further information: www.aurion.fi 


31

processes 

Generating grinding of 

double helical gears 

In future generating grinding can also be used under certain 

conditions to produce double helical gears. This means Liebherr- 

Verzahntechnik GmbH is expanding its range of processes for hardfinishing 

for this gear type to meet the very highest quality requirements. 

Compared to established processes such as profile grinding 

or hard milling, generating grinding is much faster and therefore 

also provides an interesting alternative from a commercial 

perspective. 

Double helical gears combine the advantages of both spur gears and helical 

gears: transferring of high forces, quiet running behavior due to increasing 

the contact ratio and a reduced axial bearing load. They are used wherever 

a high power density is required from the gears. Their range of applications 

extends from very small, lightweight and compact parts in aerospace to 

powerful turbo transmissions and very large-scale applications in energy 

and materials handling technology. 

Generating grinding – an efficient alternative 

Today, due to increased quality requirements in terms of their efficiency, 

quiet running and noise development, double helical gears increasingly need 

to be hard-finished. For manufacturing reasons only 4 or 5-axis hard milling 

is possible for continuous double helical teeth with no gap between the top 

and bottom gears. Profile grinding has become established in most cases for 

double helical gears. Liebherr-Verzahntechnik GmbH has now succeeded in 

developing generating grinding as a precise and efficient alternative for this 

hard-finishing. 

Generating grinding as a genuine alternative in hard-finishing 

With Liebherr having already optimized the soft machining of double helical 

gears by means of precise correction measurement in gear shaping, the company 

is now taking hard-finishing to a new level: the cycle times can be up 

to ten times faster when compared to profile grinding. The quality produced 

meets the very highest accuracy and surface 

roughness requirements. The workpiece simply 

has to meet the following requirements: the 

distance between the two gears is at least 23 

millimeters and the module must not be larger 

than 5. 

High-performance cutting materials 

This has been made possible, for example, due 

to the development of robust grinding materials 

enabling the economic application of 

worms with a very small diameter. Trian gular 

or rod-shaped sintered corundum grinding 

material or CBN (cubic crystalline boron nitride) 

with a galvanic or ceramic bond are 

used as cutting materials. Liebherr is able to 

offer the optimal cutting material according 

to the application and requirements. 

Two grinding worms on one arbor 

To ensure minimal tool overtravel, two 

grinding worms are used whose lead direction 

matches the gears to be ground in each 

case: the left-handed gear on the doublehelical 

is machined with a left-handed grinding 

worm, the right-handed gear is machined 

with a right-handed grinding worm. The two 

grinding worms are on a long arbor and are 

controlled by software with the gear being 

machined consecutively, in one clamping. 

Each of the two worms can both rough and 

finish the workpiece. 

Advantages of generating grinding: 

significantly shorter grinding times 

more resistant to stock variation and 

hardening distortions 

lower risk of grinding burn 

efficient manufacture of 

topological modifications 

improved accuracy in the apex point and 

in the angular position of gear teeth 

excellent individual pitch accuracy, and 

cumulative pitch overall quality 

potential for finish grinding and polishing 

to improve surface quality 

combination with fully automatic stock 

and material removal check possible 


processes 

Generating grinding with LHGearTec: simple and intuitive 

the method is more resistant to stock variation and distortion 

due to heat treatment. In addition to the precise apex point 

it also achieves much greater precision in the angular position 

(index) of the two gears in relation to one another. It also 

improves the surface roughness and provides greater stability 

when grinding the dedendum contour. The individual qua - 

lity of the lead and the lead quality overall is very high thanks 

to the continuous process. This means that topological modifications 

such as specific end reliefs or twist-free grinding can 

be manufactured economically. The risk of grinding burn is 

also lower. 

Robust, dressable CBN grinding worm 

The worms are designed in the CAD model with the aim 

of maximizing their outside diameter and their length. “We 

approached the design of the worms with the view that 

ultimately we were just adding another gear with another 

helix angle – as simple as that. We tried that out, and the 

trials were successful”, says Dr. Andreas Mehr, an expert in 

gear grinding at Liebherr, recounting the development with 

a slight twinkle in his eye. 

Highest quality in gear geometry 

In the generating grinding process itself, the grinding of the 

upper gear is completed first. This serves as a reference for the 

angular position of the two gears in relation to one another. 

Via an adapted centering process the lower gear is then very 

precisely ground with position orientation in relation to the 

first gear. Machining both in one clamping fixture enables 

an outstanding pitch to be achieved. This means that the 

distance, for example, from one left tooth flank to the next 

is virtually perfect. The axial position of the gear wheels in 

relation to one another – the apex point – is achieved using 

this technology with a very high degree of precision. 

Besides the significantly faster machining times, generating 

grinding has other advantages compared to profile grinding: 

Grinding head and software requirements 

For the generating grinding of double helical gears, a powerful 

and dynamic grinding head with a counter bearing 

is required which enables machining with both small and 

long grinding worms. Liebherr’s newly designed GH 240 

CB grinding head is suitable for this. It has both main and 

counter bearings to rigidly clamp the tools, and achieves 

a maximum spindle speed of 12,000, or even the option of 

17,000 revolutions per minute. Just as important is software 

with simple entry and correction options which are easy to 

understand, which is designed for double helical gears and 

which enables individual gears and their angular position 

to be corrected in relation to one another. With the relevant 

programming, the regrinding function even enables the first 

part to be manufactured as a good part. 

Retrofittable in existing machines 

The process can be retrofitted on existing Liebherr LGG 

gear grinding machines provided they are fitted with the 

GH 240 CB grinding head and the LHGearTec control system. 

Its design, shift length and the option for also clamping 

small grinding worms mean the grinding head is the essential 

basis for the generating grinding of double helical gears. 

The company examines every use case individually and helps 

to achieve the highest quality using its expertise and its process 

know-how. “We can develop a tailored solution for every 

customer”, explains Dr. Mehr. 

GrindingHub 2024, hall 7, booth B36 

further information: www.liebherr.com 


33

processes 

Innovative milling technology for 

weld seam preparation 

With the expansion at the production site in Bilbao, 

Haizea Wind Group is making the port one of the most 

important locations in southern Europe for the construction 

of offshore wind towers and their foundation 

structures (monopiles). 

Haizea Wind Group (Haizea), which was founded in 2017, 

has been working with Graebener right from the start. In 

2018 Graebener already supplied a 55 kW longitudinal 

seam milling machine and two 55 kW circumferential seam 

milling machines for Haizea’s wind tower production in Bilbao. 

Haizea is now entering the monopile market and is once 

again relying on two further milling machines for weld seam 

preparation from the custom machine builder from Germany, 

this time with a recently developed pipe turning device 

for turning and positioning cylindrical and conical pipes, 

which is used to align the pipes above the longitudinal seam 

milling machine for seam processing. The pipe weight can be 

up to 125 tons. 

Haizea is a global player in the onshore and offshore 

industry. The company has been manufacturing giant wind 

towers in the port of Bilbao since 2018. By entering into 

monopile production, the company is expanding this facility 

by adding another hall segment. Production is scheduled to 

start in the second quarter of this year. 

Graebener supplied a 55 kW longitudinal seam milling 

machine including an innovative pipe turning device, which 

is designed for turning and positioning cones. The scope of 

supply further includes a 55 kW circumferential seam milling 

machine with a special height adapter and a substructure that 

Graebener ® is a medium-sized, family owned machine 

building company with locations in Netphen (Germany) and 

Houston (USA) as well as a variety of international representatives. 

With over 100 years of experience in the metal 

processing business they develop and realize customized 

solutions for the core markets of automotive industries, 

hydroforming, manufacturing of large pipes, shipbuilding, 

wind tower production, vessel construction and hydrogen. 

The product range includes hydraulic forming machines, 

milling and bending machines, calibration and straightening 

presses as well panel production lines. In addition the 

company has been one of the first to focus on the research 

and development of manufacturing processes and machines 

for fuel cell and electrolyzer components, such as metallic 

bipolar plates. With the business unit Graebener ® Bipolar 

Plate Technologies the company has dedicated itself to setting 

the quality standard for these manufacturing technologies. 

Innovative processes help manufacturing components for 

hydrogen-based energy generation that are tailor-made, 

integrable, scalable and thus economically efficient. 

Thanks to the height adapter, sections with pipe diameters 

of 6 to 12m can be processed with the 55kW circumferential 

seam milling machine 

enables the circ seam milling machine to be positioned and 

aligned quickly to the circumferential seams of the monopile 

sections to be processed by means of a self-propelled modular 

transporter (SPMT). The machines are designed to prepare 

the connecting seams of the huge cones and cylinders that 

make up the monopiles for the submerged arc welding process. 

Monopiles, in turn, are foundations for offshore wind 

farms – large steel columns with a wall thickness of up to 

150 mm, diameters of up to 15 m, lengths of up to 100 m and 

unit weights of up to 2,500 t. 

Optimum conditions for economical weld seam 

preparation with large wall thicknesses 

Monopiles consist of a large number of steel rings (pipe sections) 

that are welded together. Due to their huge diameters 

of up to 15 m the sections are made from several individual 

plates. This production method results in both longitudinal 

and circumferential seams: longitudinal seams during the 

production of the shells, circumferential seams when joining 

the sections together. Both inside and outside edges must 

be precisely beveled prior to welding the individual parts 

together. The more precise the bevels, the more resilient the 

weld seams and therefore the complete monopile will be. 

The seam milling process provides a uniform joint width 

and depth over the entire circumference of the pipe. The precisely 

milled joints allow an uncomplicated visual inspection 

of the internal root of the weld seam without prior cleaning, 


processes 

enabling the quality of the internal weld seam 

to be visually inspected directly. Weld seam 

defects can be reduced to 0 %. Automatic 

seam preparation is a necessary requirement 

for an automatic multi-wire submerged arc 

welding process, given the fact that the seam 

detection sensor requires clean joint edges. 

Another advantage of Graebener seam 

milling machines is the cost savings of at least 

62 % compared to conventional methods such 

as carbon-rod joints or grinding. The reason 

for this is the geometry of the milled seam 

preparation: the much smaller joint width – a 

milled joint has an opening angle of 16 °, 

whereas a conventional joint has an opening 

angle of approx. 60 ° results in less heat input, 

less welding material being used, energy being 

saved, and the welding time being significantly 

reduced. Furthermore, at up to 1.2 m/ 

minute, mechanical milling is ten times faster 

than conventional processes. 

Efficient handling of 

large diameter cones 

Graebener is the global market leader with 

its circumferential and longitudinal seam 

milling machines since many years. Both 

types of machines are able to process large pipe 

diameters with very thick material. Haizea is 

receiving two further developments: 

One special feature is the innovation developed 

by Graebener in 2022 for its longitudinal 

seam milling machines: the integrated pipe 

turning device, which allows even conical 

pipe sections to be positioned more securely 

without crane handling and without lateral 

drift. On a milling machine, each longitudinal 

seam of a pipe section (up to three pieces 

depending on the diameter) have to be rotated 

into an exact 6 o’clock milling position for 

processing. This is usually achieved by means 

of cranes. However, an integrated device facilitates 

the positioning of the pipe sections significantly, 

allowing the turning process to be 

carried out with considerable time savings. 

Using the turning device, the cylindrical and 

conical sections are safely lifted, turned and 

lowered in a defined manner – even sections 

with very large diameters, cone angles of up 

to 6 ° and a unit weight of up to 150 tons. As 

turning conical pipe sections geometrically 

causes a drift in the longitudinal direction 

of the pipe, Graebener has developed special 

rollers that turn the pipe section and prevent 

the longitudinal drift altogether. The rollers 

are positioned by means of electromotive servo 

drives so that the conical pipe sections only 

roll on the largest and smallest pipe diameters 

on the surface line. The rotation speeds 

The Graebener longitudinal seam milling machine is used to prepare 

weld seams on monopile pipe sections with very large diameters, 

cone angles of up to 6 ° and a unit weight of up to 150 tons 

are automatically adjusted to prevent drift in the longitudinal direction of 

the pipe. The second innovation – a special height adapte – enables the customer 

to process pipe diameters of very different sizes on the circumferential 

seam milling machine. To assemble sections of cylindrical and conical 

sections, these have to be positioned on a constant horizontal center line. As 

a result, the different diameters of the cones cause different working heights 

for the circ seam milling machine. 

With a specially developed adapter, the milling machine can be positioned 

at two different heights on the pipe sections. A substructure placed underneath 

allows the milling machine including adapter to be moved with the 

help of a self-propelled modular transporter. 

Just like over 200 customers from the vessel, large-diameter pipe, wind 

and offshore sectors worldwide, Haizea Wind Group has been relying on 

the proven Graebener technology for years. With these new machines the 

company is equipped for future monopile production. 

further information: www.graebener.com 


35


Perfecting the entire 

machining process on the stator housing 

Unusually sophisticated components and highstrength 

materials for high-tech applications, like 

stator housings for electromobility with ensured 

quality in the range of microns, are among the machining 

challenges tackled by the specialists at 

Bharat Forge Daun. Right in the middle of it all: 

several vertical turning machines from EMAG, which 

are in operation around the clock, five days a week. 

With production demands like these it is obvious that service 

from EMAG is particularly important. But what exactly 

was the deciding factor in the decision to invest in these 

machines? 

Complexity is something of a hobbyhorse at Bharat Forge 

Daun: the company, based in the heart of the Eifel region, 

around 50 km from Koblenz, produces rotationally symmetrical 

series components as a contract manufacture as well as 

tools and moulds, which are then used by the forging experts 

at Bharat Forge CDP and Bharat Forge Aluminiumtechnik, for 

example. This means that challenges like difficult surfaces 

and positional arrangements are common. “Extreme accuracy 

requirements in the micrometer range are always part of our 

work”, says Christoph Steffens, head of mechanical engineering 

at Bharat Forge Daun, summarizing the initial situation. 

“In this context we monitor the processes very comprehensively, 

carry out many measurements and even accompany 

the component development on request – so that the production 

of the component runs efficiently. We offer this expertise 

on the market for sectors such as the automotive industry, 

general mechanical engineering and the production of 

agricultural machinery.” 

Efficient machining of forged stator housings 

A stator housing used in the hybrid drive of a large German 

automotive company shows what this means in concrete 

terms. Even at a first glance it is clear that its pot-like shape 

and various geometric details are sophisticated. What’s more, 

the blank is a forged steel component – a rarity in this field 

of application. Its material properties are an additional challenge 

for the south-west German machining experts. In addition 

the client has continuously increased the required 

quantities over the years (and will continue to do so). So how 

do you combine accuracy, efficiency and process reliability 

in this environment? Bharat Forge Daun’s answer has a lot 

to do with EMAG’s mechanical engineering components, as 

the specialists have been 

relying on EMAG lathes 

for some time. 

The blank is a forged steel component 

Work area of the VL 8 at Bharat Forge Daun 

Vertical design with 

decisive advantages 

The vertical design of 

these solutions played 

an important role in 

the investment decision. 

The horizontal machine 

from another manufacturer 

had caused some 

difficulties in the past. 

For example annoying 

chip clusters regularly 

formed, which had to be 

removed manually two 

to three times per shift. 

“It was therefore obvious 

to us that we should 

carry out these processes 

in machines with a vertical 

design, because 

their unhindered chip 

flow prevents many 

disruptions. Our objective 

was to achieve maximum 

process reliability”, 



emphasizes Steffens. The decision in favor of EMAG was also 

based on existing know-how: the machine manufacturers 

used examples from other customers to show how stator 

machining is carried out in their machines – with low 

non-productive times and high-precision handling processes. 

Integrated automation including a pick-up spindle and lateral 

conveyor belt ensures fast processes, while the stable 

base body made of the polymer concrete Mineralit® stands for 

quality in turning and milling processes. 

EMAG service in focus 

Last but not least the response time and the expertise of 

EMAG’s service department play an important role for 

Bharat Forge Daun. A regional service technician is always 

on site within a few hours and solves any problems directly. 

“The machines are very robust. Nevertheless this issue is important 

because we produce five days a week in three-shift 

operation and so far we have always been helped with minor 

faults in record time – for example with a defective light 

barrier. The repair has never taken longer than two hours”, 

The circulation belt of the VL machines also serves 

as a parts store 

says Christoph Steffens, who also reports that EMAG has 

already been on site via remote service. 

GrindingHub 2024, hall 9, booth C31 

further information: www.emag.com 

A new era in casting and machining technology 

Fill is internationally successful as a specialist 

machine builder and systems integrator for a variety of 

industries and applications. 

Synergy between the various industrial sectors and material 

families fosters continuous cross-industry innovation. At 

Euroguss 2024, Fill presented a whole range of innovations in 

foundry and metal machining technology. 

Passion as the key to innovation 

“Our development departments bring great enthusiasm to 

their work on their projects. This continuously leads to new 

solutions, with production and processing systems constantly 

being further developed. The result? Decisive competitive 

advantage for our customers. They not only bring their products 

to market faster, but also in a targeted manner. The 

numerous international visitors to Euroguss 2024 were 

able to see this with their own eyes. The feedback was outstanding”, 

report Competence Center managers Friedrich 

Dallinger (Metal Machining Technology) and Thomas Rathner 

(Foundry Technology). 

The SYNCROMILL all-rounder 

The wide variety of machines and systems “made by Fill” in 

casting and machining technology impressed the international 

trade visitors. The flexible machine concept of the 

SYNCROMILL C21-63/600 Y1200 machining center could 

be experienced live in action. With a 600 mm spindle spacing 

and 1,200 mm of Y-travel, it was primarily developed for 

the high-precision machining of elongated electronic casings 

and profiles made of die-cast metal. The interlinking 

with upstream or downstream processes can be adapted flexibly 

to meet individual customer requirements. The company 

also offers the most efficient solutions for the machining and 

automation of megacast and gigacast parts. Equipped with 

optimal clamping and tooling concepts and specifically tailored 

automation components, the SYNCROMILL machining 

technology is the state of the art. For best possible yield 

Fill offers the use of highly flexible, driverless transport systems 

(FTS) as well as robot or portal solutions. Retooling for 

the implementation of future components is thus already a 

part of the system concept. 

FILL CYBERNETICS – a new level in digitalization 

The CYBERNETICS products are a key component of Fill’s 

machines and systems. CYBERNETICS covers the entire 

bandwidth of required solutions – from the monitoring of 

complex individual operations to automated system optimization 

using artificial intelligence (AI). The special combination 

of high-tech mechanical engineering and digital tools 

results in enormous added value. 

further information: www.fill.co.at 


37


Empowering e-mobility industry 

written by Jianing Wu 

Tuopu Group is a technology-leading automobile 

parts company committed to innovative manufacturing 

capability on power chassis systems, interior 

and exterior systems, and intelligent driving control. 

Founded in 1983 Tuopu has been committing to excellent 

quality and service. 

Thanks strategy and the strong foresight of e-mobility industry 

Tuopu grows rapidly with the main NEV OEMs in China, 

USA and Europe, such as Geely, BYD, Li, NIO, Hiphi, Rivian, 

Lucid, Volvo etc. 

“To develop products like knuckle and subframe with our 

customers within a very short period, we decided to invest in 

reliable CNC machining centers and the latest technologies. 

LiCON is obviously our first choice at this strategical moment”, 

explains Tuopu management team. Right after investigation 

and visiting reference customers, Tuopu placed orders 

of the first 10 machines to LiCON in 2018. After the successful 

run-off of knuckle production in the big Shanghai area, 

further 19 LiCON machines were purchased for diverse subframe 

lines in the last three years. The following advantages 

of LiCON machines are so significant that they have been 

widely spread in Chinese e-mobility industry. 

Complete machining in only one clamping 

LiCON is well known as one of the top German 5-axis machining 

center builders among the Chinese customers. The 

complete machining of complex chassis structural parts requires 

not only the machines but also the fixtures and process 

know-how, which are exactly LiCON’s core competences. 

Back in 2018, as a new player in lightweight chassis structural 

parts, Tuopu teams already relied upon LiCON’s expertise 

in this phase. For knuckles made of aluminum alloy LiCON 

provided double spindle solution with pallet changer, which 

Tuopu headquarter in Ningbo 

allowed the parallel loading/unloading while machining, 

and the complete machining of LH/RH parts on every single 

machine. All fixtures and toolings are well designed to fit one 

clamping concept. 

For high pressure die casted subframes LiCON provided a 

single spindle solution with direct load, which offered an interference 

diameter of 1600 mm in A- and B-axis. This design 

allowed to clamp the parts vertically on the bridge, which is 

tailor made into a narrow version. This remarkable combination 

allowed the machining of six sides of the complex subframe 

within one clamping. The digitally developed fixtures 

were designed and manufactured in LiCON Germany. They 

worked perfectly in terms of lightweight, stiffness, dynamic 

balancing, easy access and the hidden fluid lines. “The whole 

package from one interface of LiCON is the most important 

decision of this project, which leads to our huge success of 

LiCON machining centers in Tuopu workshop 

Subframe fixture 



subframes for electrical vehicles. Based on what we learned 

from LiCON, we can now develop one clamping concept for 

the other structural components”, confirms Jun Zhao, operation 

director, R&D Power Chassis System. 

Environmentally friendly technologies 

“Our mission is to provide more secure, comfortable, and 

environmentally friendly technologies and products for cars. 

That is why we always look for green manufacturing technologies. 

LiCON is the perfect strategical partner for us when it 

comes to this topic”, says XinXin Li, GM business unit subframe. 

All 29 machines are equipped with minimum quantity 

lubrication (MQL) system and LiCON ECO-mode, which are 

helping Tuopu to save energy consumption by approx. 40 %. 

Unlike the conventional lubrication with emulsion, the dry 

metal chips by MQL can be recycled easily without any further 

cleaning and drying process. The filtration and disposal 

process of emulsion residue are saved as well. Furthermore, 

the workshops are kept very clean and dry despite 3 shifts x 

7 days/week production, and therefore have become the show 

rooms in Tuopu. “Our EHS management team is particularly 

satisfied with LiCON technologies”, confirms XinXin Li. 

Highest machining quality and 

performance in production 

For more than 60 years LiCON is well known for engineering 

development and manufacturing from Germany for 

the world. Tuopu believes in LiCON’s philosophy of “Made 

in Germany”. The machining quality as well as the process 

stability have been excellent right from the beginning. As 

more and more diverse CNC machines and automation lines 

have been running for chassis parts production in the big 

Shanghai area, Tuopu finds that LiCON machines are the 

most outstanding among all international and domestic 

suppliers in terms of machining quality, overall equipment 

effectiveness and mean zime between interruption. Besides, 

the LiCON machines are very easy to handle both in manual 

mode and automation line. This is very important for Tuopu 

because the Tier 0.5 supplier has not only serial production 

but also a small batch of trial machining, which requires 

operators to work manually on the machine. Based on the 

performance of LiCON machines, Tuopu is able to increase 

production capacity by nearly 50 %. “The LiCON machines 

can operate with greater precision and reduce the amount 

One of the 29 LiFLEX I 12126 machining centers 

purchased from Tuopu 

of waste during the manufacturing process. This results in 

higher quality products, faster lead times and, ultimately, in 

higher profit. Although the price of LiCON machines is the 

highest among all suppliers, we are ready to pay for the top 

quality”, announced Tuopu management team on the Key 

Suppliers Conference in August 2022. 

Localized LiCON organization in China 

LiCON knows the importance of providing exceptional service 

to its Chinese customers. That’s why they have established 

local organizations in Shanghai, Beijing and Changchun 

to provide quick and effective support to their customers. 

For Tuopu LiCON has established a local organization in 

Shanghai to cater to their needs. Their team of engineers 

are readily available to provide technical assistance, maintenance 

and repair services for the LiCON machines. The company 

also offers training programs for Tuopu’s employees 

to ensure they know how to operate the machines to their 

full potential. This enables Tuopu to maximize their 

productivity and get the most out of their investment in 

LiCON CNC machines. 

“In addition to these services LiCON also takes feedback 

from us seriously. They frequently communicate with us to 

understand our needs and feedback on the CNC machines”, 

says Kent Ke, operation director business unit subframe. 

Subframe line with LiCON machining centers 

in Tuopu workshop 

This work ethics helps LiCON continue to innovate and 

improve products for better serving the customers worldwide. 

Overall, LiCON is committed to providing exceptional 

service to the customers and Tuopu is a great example of 

how LiCON goes above and beyond to ensure customer 

satisfaction. 

further information: www.licon.com 


39


High precision grinding for a 

sustainable and digitalized future 

For more than 120 years Fives has been leading the 

industry with innovative grinding machines. From 

May 14 – 17, 2024, GrindingHub in Stuttgart, Germany, 

will be the perfect opportunity for Fives to showcase 

their complete range of grinding solutions and to 

demonstrate their latest technological developments in 

booth B31 in Hall 9. 

With a strong heritage built on globally renowned technologies 

– Landis, Giustina, Daisho, Cranfield Precision, Bryant, 

Cincinnati, Gardner and CITCO – Fives provides an extensive 

range of grinding solutions engineered with exceptional 

stiffness and high thermal stability to ensure high precision, 

minimal scrap and maximum efficiency. This offering is complemented 

with a complete line of CITCO tools and Gardner 

abrasives custom-engineered tooling solutions. 

From cylindrical to single & double disc, ID/OD, orbital, 

centerless and optics, Fives’ Grinding|Ultra Precision technologies 

serve a wide range of applications and materials 

for various industries, including e-mobility and automotive, 

green energy, rail, marine and defense. 

As a global partner with eleven Grinding|Ultra Precision 

facilities and localized service centers in Europe, 

North America and Asia, Fives is dedicated to its customers’ 

success, wherever they are, from engineering, operation to 

support program and service throughout the entire life cycle 

of their installations. 

Fives is always one innovation ahead 

With over 140 active patents, Grinding|Ultra Precision is 

always one innovation ahead, continuously evolving proven 

technologies and developing new ones to meet customers’ 

needs and to support market requirements in terms of digitalization 

and sustainability. 

landis 18 Ω 

Electric vehicle drive units, bearings, wind turbine components, 

hard coated brake discs, semi-conductors and optics 

are among the new applications Fives’ machines are adapted 

to, grinding a variety of precision components with increased 

efficiency and flexibility. 

Newly released Landis 18 Ω for precision shafts 

including electric vehicle drive solutions 

The automotive industry is facing unprecedented uncertainty 

in the manufacturing requirements for EV powertrain 

components. Investments need to go further to continue ICE 

production while simultaneously developing products and 

manufacturing capability for EVs. 

In response to customers’ needs, Fives has developed 

the Landis 18 Omega for precision shafts including electric 

vehicle drive solutions. This cylindrical grinding machine 

combines many benefits: higher output with lower energy 

consumption; industry-leading power to size ratio; reduced 

floor space and man-power requirements; plus the lowest 

Total Cost of Ownership, and at an affordable price point. 

Giustina VDD760 for new, 

low dust emission hard coated brake discs 

From 2030, Hard Coated Brake Discs will be a critical element 

to comply with the recently-ratified Euro 7 automotive 

norms, which set limits on the air pollution from new 

vehicles sold in the EU. This technology significantly reduces 

particle emissions from brakes, but creates challenges in 

manufacture. 

In response to the requirements of the Euro 7 standards, 

Fives has further developed a technology to grind hard 

coated brake discs. This new Vertical Double Disc grinder 

benefits from Fives Daisho Seiki strong experience and proven 

industrial technology for conventional cast iron brake disc 



Giustina XL-VSD 

grinding that has been in production for many decades. With 

a reduced footprint, Giustina VDD760 features new working 

parameters and new abrasive wheel specifications, to offer 

optimized productivity and high-quality performance. 

Giustina XL-VSD for large bearings in the 

wind turbine market 

Targeting the green energy sector, Fives has specifically 

designed the Giustina XL-VSD for grinding large bearings 

used in the wind turbine market. This extra-large Vertical 

Single Disc offers an advanced range of sizes to grind bearings 

from 1 up to 4 meters and beyond, with exceptional 

parallelism and flatness. 

Advanced digital solutions to track machine & 

process health and optimize machine parameters 

To facilitate its leading role in the future of grinding technology, 

Fives provides an advanced Digital solution. Fives CortX 

product range includes a suite of hardware and software solutions 

tailored to specific needs, with the capability to connect 

seamlessly and agnostically with any control system to gather 

high-frequency CNC and PLC data. Solutions are available 

from simple dashboards, OEE tracking, energy monitors and 

condition-based maintenance modules – to track machine 

and process health; all the way to Predictive Maintenance 

systems, and fully adaptive machine-learning solutions that 

automatically optimize machining parameters to improve 

quality based on auto-detection of the state of the grinding 

wheel or cutting tool. 

At GrindingHub Fives will also showcase its large range 

of custom-engineered tooling solutions, including CITCO 

cutting tools, Natural, CVD & peerless diamond dressing 

tools and Gardner abrasive and superabrasive solutions for 

disc, fine, OD/ID and tool-cutter grind applications. 

GrindingHub 2024, hall 9, booth B31 

Giustina VDD760 

further information: www.fivesgroup.com 


41


“Stay connected” 

The UNITED GRINDING Group will once again be 

represented with a prominent booth at GrindingHub 

under the motto “STAY CONNECTED”. 

This year the group will be unveiling an innovation in the 

field of tool machining from its WALTER brand on the first 

day of the trade show, May 14, 2024 at 10 a.m., in hall 9, 

booth C51. 

At GrindingHub the UNITED GRINDING Group will be 

presenting the latest technologies from the fields of grinding, 

eroding, measuring and additive manufacturing with 12 

machines. The motto of this year’s trade show appearance is 

“STAY CONNECTED” and therefore the focus is on connectivity 

solutions, which will be presented on 840 m 2 . In addition 

to digital assistance systems – the UNITED GRINDING 

Digital Solutions – interested visitors can find out about 

digital Customer Care solutions or how machines can be 

con nected to one another and with their production environment 

via the 

univer sal manufacturer-independent 

umati data interface. 

Along with 

WALTER machines 

for tool machining, 

machines from the 

STUDER brand 

for cylindrical grinding and BLOHM for surface and profile 

grinding will be on display. The group will also present its 

additive machine tool for the industrial 3D printing of metal 

parts, the IMPACT 4530, from its IRPD brand. Visitors will 

be able to see the intuitive machine operation at the C.O.R.E. 

panel and win a PlayStation PS5 in the process. 

GrindingHub, hall 9, booth C51 

further information: www.grinding.ch 

Fritz Studer Award 2023 – 

innovative grinding technologies 

Fritz Studer AG has awarded its research prize, 

the “Fritz Studer Award”, for the seventh time. Applicants 

from several European countries submitted their 

work. Dr. Emil Sauter won the award and the prize of 

CHF 10,000. 

The Fritz Studer Award is aimed at graduates from European 

universities and technical colleges. 

The Fritz Studer Award 2023 was presented to Dr. Emil 

Sauter from the Institute for Manufacturing Technology and 

Machine Tools at ETH Zurich. He impressed the entire jury 

with his topic. “Detection and avoidance of thermal damage 

Detection and avoidance of thermal damage for 

high-performance metal grinding processes using 

hybrid machine learning models 

for high-performance 

metal grinding 

processes using hybrid 

machine learning 

models.” 

His work deals 

with the development 

of an innovative 

condition monitoring 

system for 

external cylindrical 

grinding with metalbonded 

CBN tools, 

Dr. Emil Sauter, winner of the 

Fritz Studer Award 2023 

which recognizes 

thermal damage in 

situ and predicts the remaining useful life of grinding tools 

with relative accuracy. Process parameters such as structureborne 

noise, spindle current, force characteristics, etc., and 

the use of time-frequency transformations generate process 

features of a grinding process to detect different stages 

of thermal damage to the workpiece with high accuracy. The 

remaining tool life can also be estimated. In general, this 

work with its many industry-oriented practical tests also 

shows that machine learning methods can lead to higher 

productivity and improved component quality in grinding 

technology. 

further information: www.studer.com 


Resource-saving ultra-fine filtration 

technology for regrinding precision tools 

components 

Cleanly filtered cooling lubricants play a decisive 

role in the regrinding of tools and represent an 

important quality factor. The filter manufacturer 

Vomat from Treuen uses high-performance ultrafine 

filtration technology to ensure that purified cooling 

lubricants of the highest purity are always available 

throughout the entire production process. The 

Vomat FA 70+ small system is particularly suitable for 

regrinding. 

This single-station solution in compact dimensions combines 

special design features that enable tool manufacturers and 

resharpeners to produce in a resource-saving and profitable 

manner. 

The dovetailing of climate and environmental protection 

with production efficiency and profitability in industrial metal - 

working is becoming increasingly important. One piece of the 

mosaic is the regrinding of cutting tools. This process helps 

to reduce the environmental impact at various stages of the tool 

life cycle, which in turn helps to reduce the CO 2 

footprint. 

This leads to increased demand from the industry for tool 

reconditioning services from tool manufacturers and companies 

specializing in regrinding, because professional reconditioning 

and resharpening of high-priced precision cutting 

tools maintains their performance beyond their initial use 

and the performance potential is fully exploited thanks to the 

extended life cycle. Steffen Strobel, sales manager at the machine 

and filter manufacturer Vomat from Treuen: “We welcome 

this trend as it effectively saves resources. At the same 

time the integration of climate and environmental protection 

into production profitability is also becoming increasingly 

important in the production of cutting tools and their resharpening. 

More and more tool grinders and resharpeners 

Optional 

additional 

modules such 

as an integrable 

7 kW cooling unit 

with a control accuracy 

of +/- 1.0 K enable 

customer-specific complete system solutions 

are attaching importance to the fact that their machines not 

only offer high efficiency and quality, but also produce sustainably. 

This applies not only to tool grinding machines but 

also to peripheral systems such as coolant filtration systems. 

This is where high-performance filter manufacturers like 

Vomat come in. The product portfolio of the Treuen-based 

filtration specialists includes solutions for individual systems, 

modular systems, central systems and customer-specific 

special systems with central and decentralized functions. 

Thanks to numerous design advantages the filters enable sustainable 

and at the same time profitable tool production and 

preparation. The FA 70+ stand-alone solution for tool resharpening 

is an example of this. 

The compact system (dimensions l x w x h: 1300 x 1100 x 

1200 mm) has a maximum filter capacity of 70 liters/minute 

and provides clean oil in NAS 9 quality over a long filtration 

period. Optional additional modules such as an integrable 

7 kW cooling unit with a control accuracy of +/- 1.0 K as 

well as magnetic and disposable filters enable customer-specific 

complete system solutions. The residual sludge is manually 

disposed in special bag containers. 

Steffen Strobel: “State-of-the-art filter, cooling and disposal 

technology – including HSS pre-filters for mixed processing 

if required – ensure economic and ecological success in harmony. 

In addition our VOMAT Filter FA 70+ is low-maintenance 

and takes up very little valuable production space 

thanks to its compact design.” 

In order to optimize the operation of the ultrafine filtration 

systems in terms of energy, Vomat relies on the use of 

efficient pumps with high efficiency. Together with the optimized 

process control, unnecessary energy losses are avoided: 

Vomat systems automatically control the filter flow and backwash 

cycles as required. This extends the service life of the 

filter elements and saves energy and costs. At the same time, 

less heat is added to the medium, which in turn requires less 

cooling capacity and further reduces energy consumption. 

Steffen Strobel: “The fully automatic control and regulation 

of the filter capacity means that energy and operating costs 

can be kept low. The filtration systems for tool grinding and 

regrinding are tailored to the user’s specific requirements 

and integrated into their production process. Thanks also to 

the high quality of the cleaned coolant during grinding, the 

reground tools achieve a performance that comes very close 

to that of a new tool.” 


further information: www.vomat.de 


43

components 

A customized grinding solution 

for tap manufacture 

Projected global demand for products such as 

taps, dies and thread forming tools is anticipated to 

rise from 2.75 billion to 3.42 billion over the next five 

years, with a compound annual growth rate (CAGR) 

of 5 %. The high-tech industries, particularly automotive 

and aerospace sectors, are expected to sustain a 

significant portion of this growth, accounting for 16 % 

of the overall market demand. Additionally there is an 

expected increase in demand from medical applications, 

which is projected to contribute another 7 % to 

the total market share within the next five years. 

Given the impetus from these high-tech markets, tap producers 

will need to enhance their designs to meet the escalating 

market share of specialized materials. Notably, composites 

(expected CAGR of 8.5 %) and super alloys (expected CAGR 

of 7.5 %) are anticipated to experience the most substantial 

growth, necessitating the development of tailored designs in 

response. 

With the boom of automotive and aerospace applications 

ANCA sees great potential for the future of the high-end tap 

market. ANCA’s years of experience working with tap manufacturers 

has given the company valuable insights into the industry 

challenges, making it well-equipped to offer the right 

solution. The TapX is a machine specifically designed and 

integrated with automation to ensure high productivity in 

mass production. As a one-machine solution with single 

clamping, it guarantees substantial benefits for manufacturing 

standard and special taps by eliminating the traditional 

requirement of needing several grinding machines. 

ANCA Tap software includes a Wizard to help you get up 

and grinding taps in a few easy steps 

Flexible, precise and efficient one-stop tap grinding is 

simply unimaginable on ordinary grinding machines, as 

high-speed steel taps, carbide taps, micro taps and non-standard 

taps require different and detailed solutions. The difference 

lies in the performance of a single grinding process, 

a parallel grinding process or a combined grinding process. 

In addition several grinding machines are usually required, 

each performing a specific tap grinding task. TapX integrates 

the various processes into one machine. 

Flexibility is a key feature of the tap grinding process on 

the TapX. The specially designed machine and powerful 

ToolRoom software ensure a vast range of tap types and sizes 

can be designed and manufactured in one set-up. Combine 

this with the benefits of quick changeover time and it’s not 

hard to see how TapX can increase productivity and reduce 

lead times. 

The production of taps in different materials is an example 

of how this highly flexible solution can contribute to productivity. 

Taps are mainly made of HSS and carbide materials, 

which require high precision, surface finish and reliability 

for grinding. TapX is suitable for the complete production of 

HSS or carbide taps. With a single set-up it can grind various 

types of standard taps, micro taps and non-standard taps. Its 

excellent rigidity guarantees repeatable, high-quality results, 

while its CNC control plus programmable force of the center 

ensures reliability of high frequency movements. 

ANCA’s TapX linear for tap manufacturing 

The TapX uses ANCA’s own LinX motor technology for all 

linear axes and direct drive technology for all rotary axes. 

By eliminating all belts, pulleys and gears, the TapX is not 

only a more precise machine, but a more reliable one as well. 

Although HSS will remain the dominant material of choice, 

carbide tools are growing in popularity with the increase in 

thread milling applications and introduction of more exotic 


components 

materials. Compared with HSS, carbide offers high rigidity, 

good machining quality and long service life. Consequently, 

the production of carbide taps presents challenges for machine 

productivity, accuracy and dressing of special thread 

grinding wheels. 

TapX offers the perfect solution with its single clamping to 

optimize the grinding process. Combined with greater flexibility 

in wheel selection and process deployment, this revolutionary 

solution means more flexibility, reduced costs and 

increased tap production output. The total set-up time for 

multiple general machines is reduced from three to four 

hours to one hour for one TapX machine, which significantly 

reduces lead time for small to medium batch production, 

urgent order response and customer changes. In recent years, 

ANCA continues to innovate and has developed a unique 

solution for dome carbide taps with a wider application. Its 

superior performance is unmatched in the industry. 

Recognizing the efficiency, accuracy and reusability of 

TapX, customers have begun to expand their product range 

to include spiral, straight flute and forming taps and even 

micro parts. Micro taps are mostly used in smartphones, 

glasses, consumer electronics, aviation and military industries. 

Any miniaturized part may be machined with a small 

or micro tap. 

In recent years the growing demand for mobile devices 

and new materials has led to a sharp increase in the consumption 

of thread tapping tools, which in turn resulted 

in an unprecedented boom for machines grinding small or 

micro taps. This means that manufacturers such as ANCA, 

who have the capability to manufacture these tools, have 

great potential to meet the ever-growing market demand. To 

Flexible, efficient and one-stop tap grinding with ANCA 

grind small batches of taps, conventional machines simply 

take too long to set up. With ANCA TapX customers can 

integrate the entire process into just one machine, significantly 

increasing productivity through rapid tap design, 

set-up and changeover. It is also an excellent option to meet 

the high demand for high-quality tap products or to fulfill 

the needs of emerging manufacturers in the market. The 

TapX one-machine grinding concept provides faster tap 

design, set-up and changeover to reduce lead times and boost 

competitiveness. ANCA remains committed to offering 

comprehensive grinding solutions for its customers. 

GrindingHub 2024, hall 7, booth A70 


AI machining strategies for 3+2 axis CNC machines 

CloudNC – a manufacturing technology company 

backed by Autodesk and Lockheed Martin – announced 

that its CAM Assist solution can now create programming 

strategies and toolpaths with AI for 3+2 axis 

CNC machines. 

Previously, CAM Assist – which is available as a plug-in for 

Autodesk’s Fusion software – generated machining strategies 

with AI for manufacturers using 3-axis CNC machines, 

helping them to create programs for the machines far more 

quickly than previously possible. 

The new upgrade means CAM Assist can now provide 

strategies and toolpaths for 3+2 axis components as well, 

enabling many more manufacturers to benefit from CAM 

Assist’s efficiency gains. With 3+2 axis support in place, 

CloudNC estimates that CAM Assist helps around twothirds 

of the CNC machining market now. 

Dr. Andy Cheadle, chief technology officer at CloudNC, 

said: “This upgrade is not only a huge step forward in making 

CAM Assist even more useful for manufacturers around 

the world, but it is also an incredible technical achievement. 

From an R&D perspective, 3+2 axis support is exceptionally 

challenging, as the extra elements it involves introduce more 

potential ways of making every feature of every component, 

by several orders of magnitude.” 

CAM Assist uses advanced computer science techniques 

and AI to generate intuitive machining strategies in minutes 

or seconds, depending on complexity, which could take CNC 

machine programmers hours or days to manually create. So 

the amount of time it takes to program a CNC machine to 

make a component is greatly reduced, compared to the previous 

manual programming process, as is the time on estimating 

the costs for a new component to program. 

This way manufacturers using CAM Assist raise productivity 

and shorten lead times – saving over 300 hours of programming 

and estimating time per year. 

further information: www.cloudnc.com 


45

components 

Efficient, innovative and sustainable component 

cleaning for the entire production chain 

Whether degreasing, classic component cleaning 

or high-purity applications – the demands on cleaning 

solutions have increased in all areas of the manufacturing 

industry. Ecoclean is responding to these 

changed market requirements with an even broader 

and more modularized product range. The focus here 

is on higher cleaning quality, improved costs and more 

energy-efficient processes. 

Component cleaning is an essential manufacturing step in 

all industrial sectors to ensure requirement-compliant downstream 

processes and high, stable product quality. Regardless 

of the industry, new and modified products, increasingly 

compact and complex geometries, an ever-greater variety 

of materials, and workpiece dimensions ranging from one 

millimeter or less to several meters all contribute to the fact 

that the spectrum of required cleaning applications is more 

diverse today than ever before. The demands on the process 

and the cleanliness to be achieved vary depending on the 

production stage as well as on the product and industry. For 

example, in the final cleaning of high-tech components, including 

those for the semiconductor industry, medical, sensor 

and analysis technology, and precision optics, particulate 

contamination in the nanometer range and nanolayers of 

residual film contamination must be removed. In general industry, 

the first task is often to clean off large quantities of 

chips and machining media. Frequently, factors such as high 

throughput requirements, heavy workpieces, a widely varying 

range of components and short delivery times also play 

a role. In addition cleaning must in any case be economical, 

energy-efficient, and resource-efficient. 

Adapt cleaning solution to the task 

To optimally adapt a cleaning solution, product and company-specific 

criteria and the cleanliness specifications must be 

considered. This requires a company whose product range offers 

corresponding flexibility in terms of the cleaning media 

to be used as well as the plant and process technologies. 

As a full-range supplier of future-oriented, flexible and 

energy-efficient solutions for industrial component cleaning, 

Ecoclean and UCM, the Group’s division specializing in precision 

and ultra-fine cleaning, cover the entire spectrum of 

wet-chemical processes using water-based media, solvents 

and modified alcohols. This means that cleaning processes 

and systems, including the most suitable process and drying 

technologies for both batch and individual part cleaning, can 

be very efficiently tailored to product- and company-specific 

requirements. Process design is carried out in the company’s 

own test centers, with cleanroom test centers with adapted 

plant and measuring technology available for tasks in medical 

technology and for high-purity applications. 

Modular system makes special chamber systems 

more quickly available 

With a broad range of standardized chamber systems for 

cleaning with water-based media, solvents and modified alcohols, 

as well as a wide variety of process technologies such 

as spray and high-pressure cleaning, ultrasonics, injection 

flood washing (IFW), vapor degreasing, Ultrasonic Plus, 

Pulsated Pressure Cleaning (PPC) and plasma cleaning, 

Ecoclean covers most cleaning tasks in general industry as 

well as the automotive and supplier sectors. However, applications 

that require individually designed special equipment, 

for example due to component dimensions, throughput 

requirements, cleanliness specifications or other companyspecific 

factors, have increased significantly in recent years. 

To reduce the design effort required for this and shorten delivery 

times, the plant manufacturer has developed the innovative 

modular systems EcoCvela for water-based cleaning 

and EcoCstretch for cleaning with solvents or modified 

alcohol. For the solvent systems the modular concept 

includes four working chamber sizes with diameters from 

750 – 1,200 mm and equipment with several flood tanks. For 

individual cleaning processes the systems can be equipped 

with all process technologies available for solvent cleaning. 

With the EcoCvela the diameters of the modular working 

chambers vary from 650 – 1,500 mm. The plants can be 

equipped with several working chambers and flood tanks. In 

these highly flexible plants, various process technologies and 

systems for efficient heat recovery also ensure short process 

times and energy-saving operation. For very high cleanliness 

requirements, both plant types can also be supplied with the 

corresponding high-purity equipment. 

Modular solutions also for 

multi-bath ultrasonic cleaning 

In the area of multi-bath ultrasonic cleaning systems, solutions 

consisting of standardized modules are also offered 

in the form of the UCMBaseLine, UCMSmartLine, 

UCMPerformanceLine and UCMHighLine model series. 

With the modules for the process steps cleaning, rinsing, 

PPC, drying, loading and unloading, as well as a flexible 

transport system, cleaning systems for a wide range of applications 

can be configured and commissioned cost-effectively 

and easily. Electrical and control technology is already integrated. 

For high-purity applications, the systems are designed 

with the appropriate equipment and for operation in 

or connection to a cleanroom. Ecoclean enables companies 

from all industrial sectors to meet changing cleaning requirements 

not only in an economical and stable manner, but 

also in a resource-saving and future-oriented way. 

further information: www.ecoclean-group.net 


TMTS 

TMTS 2024 builds cross-domain ecosystem 

to seize international business opportunities 

Taiwan International Machine Tool Show (TMTS), 

organized by Taiwan Machine Tool & Accessory 

Builders’ Association (TMBA), opened grandly at the 

Taipei Nangang Exhibition Center. 

Established since 16 years, TMBA has been organizing TMTS 

biennially since 2010. Now in the 8 th edition, this year’s TMTS 

has relocated from Taichung to Taipei. TMTS continues 

to serve as a platform for connecting manufacturers with 

international buyers, aiming to foster more business opportunities 

and partnerships. 

With over 631 exhibitors participating, the exhibition had 

3,350 booths. More than 4,000 foreign buyers from over 47 

countries had registered to attend. It is expected that this 

year’s TMTS attracted over 55,000 visitors. 

(5) under TMBA’s long-term efforts in promoting industry 

standards, manufacturers have shown high recognition 

of international energy-saving regulations and actively 

engaged in product or qualification certifications, such 

as ISO 14955, ISO14064-1/-2 and ISO 14067 

The main products showcased at this exhibition demonstrated 

Taiwan machine tool industry’s continuous pursuit of technological 

innovation and transformational upgrades 

TMTS 2024 adopted the theme of “DX & GX for a Sustainable 

Future.” Under the twin axes of digital transformation 

and green transformation, it introduced an integrated exhibition 

space concept based on an ecosystem, showcasing the 

possibilities of diversified industrial applications through 

various thematic displays. 

The exhibitors showcased five major trends 

(1) tailoring comprehensive solutions for 

individual market demands 

(2) incorporating more green energy-saving technology 

applications into product designs of both machine 

equipment and accessories under the basis of 

existing smart technologies 

(3) integrating smart energy management to 

implement more efficient green processes 

(4) implementing dual-axis transformation of product 

lifecycle management (PLM), encompassing a 

comprehensive plan from product design to recycled 

packaging and carbon-reduced transportation 

This year’s exhibition was presented on an unprecedented 

scale, with not only the gathering of well-known domestic 

manufacturers but also the enthusiastic participation of 17 

cross-industry associations. Additionally, top companies 

from countries such as Germany and Switzerland have been 

invited to exhibit, bringing the latest industry trends and 

technological developments with an international perspective 

to visitors. The exhibition covered fields from hardware 

to software, providing integrated services between industries 

and comprehensive solutions, offering professionals a wide 

range of procurement choices. 

Key participating exhibitors in TMTS included Goodway 

Group, Hiwin Group, YCM, Takisawa, Victor, Tongtai Group, 

Quaser, TPI, Fair Friend Group, Buffalo, Siemens, Heidenhain, 

FANUC and Igus, etc. TMBA, in collaboration with VDW, 

has set up the “umati Zone” for the first time in Taiwan. This 

initiative highlights the tangible results of TMBA’s years of 

promoting industry standards and aligning with international 

benchmarks. 

The successful hosting of the TMTS exhibition not only 

showcased the advantages of Taiwan machine tool industry 

in technological innovation and product development but 

also highlighted the achievements of Taiwan machine tool 

industry in cross-domain integrated ecosystem development. 


47

TMTS 

TMBA has been actively promoting carbon reduction in 

the machine tool industry. “In 2022 we published Taiwan’s 

first carbon reduction handbook exclusively for the machine 

tool industry. In 2023 we initiated carbon reduction in the 

industry chain, establishing Taiwan’s first carbon reduction 

supply chain in the machine tool industry. We have announced 

the joint establishment of Product Category Rules 

(PCR) for six major product categories starting from 2024, 

aiming to align with international standards and lay the 

foundation for establishing a carbon footprint database for 

the machine tool industry. This year, we were also hosting 

the first ‘Machine Tool Energy Saving Label Evaluation’ with 

enthusiastic participation from the industry, resulting in 18 

Golden Energy Saving labels and 29 Silver Energy Saving labels 

being unveiled at this exhibition“, said Patrick P. Chen, 

chairman Taiwan Machine Tool & Accessory Builders’ Association 

(TMBA) in his opening speech. 

showing a multitude of cross-industry application elements 

to redefine the value chain of the machine tool industry. 

umati for the first time in Taiwan 

The German Trade Office Taipei (GTO), along with its 

service unit DEinternational Taiwan Ltd., had organized a 

“German Pavilion”, the largest single-country exhibition area 

in this year’s machine tool show, with 23 top German companies 

participating. To enhance visitors’ understanding of the 

exquisite craftsmanship of “Made in Germany”, two forums 

were held during the exhibition to discuss applications in the 

plastics and rubber industries and the issue of machine tools 

crossing into high-tech industries. Additionally 8 German 

exhibitors shared their products on site. 

Breaking away from the traditional product categorybased 

zoning, this exhibition was designed around the concept 

of “ecosystem”, connecting machine equipment, components 

and end-user markets in different roles and scenarios 

along the supply chain. Collaborating with 17 cross-industry 

associations, TMTS has established special exhibition zones 

such as the Metal Cutting Tool pavilion, Bearing pavilion, 3D 

Printing pavilion, German pavilion, Swiss pavilion and more, 

The German Pavilion showcased a diverse range of products 

and services, including metal cutting machine tools, metal 

forming machine tools, various machine tool components 

and accessories, as well as control systems and smart manufacturing 

systems. This included industrial robots, 3D printing 

technology and other equipments, materials and technologies 

related to machine tools. German exhibitors demonstrated 

their leadership in technology and innovation in this 

field by developing new materials or innovative components 

aimed at achieving carbon reduction and high efficiency for 

sustainable goals. Visitors had the opportunity to experience 

these cutting-edge technologies firsthand and engage with 

industry experts. 

In addition, in line with this year’s theme of “DX & GX for 

a Sustainable Future”, the German Machine Tool Builders’ 

Association (VDW) and the German Engineering Federation 

(VDMA) were invited to Taiwan and partnered with the organizers 

to set up an umati (universal machine technology 

interface) zone. This marks the first time umati has been 

exhibited in Taiwan, with a total of 26 tool machine and component 

manufacturers, legal entities and schools participating. 

umati represents a universal specification for machinery, 

aiming to establish a global standard that allows various 

equipment from different industries to connect on a single 

platform, simplifying and facilitating the transfer of data between 

machine tools, 3D printers and product management 

systems, presenting an intelligent ecosystem across fields. 


TMTS 

YCM: Leading the path to 

carbon neutrality 

As global 

competition intensifies 

the manufacturing 

industry faces a 

pivotal challenge – 

how to enhance 

productivity while 

managing limited 

resources and 

catering of diverse 

customization demands. 

At the same time there’s 

an unstoppable wave of change 

with businesses worldwide embracing the pursuit of carbon 

neutrality and net-zero carbon emissions. Considering these 

crucial issues, unveils a groundbreaking solution that redefines 

sustainable manufacturing. 

T11 Green Smart Machine 

The entire manufacturing process of the T11 incorporates 

energy-saving and carbon-reduction principles with lowpollution 

materials. A lightweight design and energy-efficient 

peripheral equipment are employed to minimize power 

consumption and reduce the carbon footprint while ensuring 

the cutting rigidity and stability of the machine. 

Notably, with the Al and loT intelligent control designed 

by YCM, the company keeps leveraging the key technologies 

of Industry 4.0 like cloud computing, big data analytics, the 

Internet of Things (IoT) and intelligent robotics of align 

with the demands. These smart manufacturing systems enable 

precise calculations of carbon emissions and footprints, 

ensuring unparalleled cutting rigidity and stability, amplifying 

production capacity and optimizing efficiency. 

With its comprehensive green technology solutions the T11 

has attained ISO14955 certification. Furthermore it has been 

recognized with the prestigious 2024 Taiwan Excellence Gold 

Award and the Machine Tool Industry Golden Energy Saving 

Label Recognition. These accolades serve as a testament to its 

commitment to energy consumption measurement standards. 

TTGroup: 

Intelligent manufacturing solutions 

The TTGroup is a global machine tool group with six international 

brands: Taiwan-based Tongtai, Honor Seiki, Quick-Tech, 

APEC, France-based PCI SCEMM and Austria-based 

Anger Machining GmbH. Their core value is to provide customers 

with total solutions. During TMTS 2024 the TTGroup 

showcased various intelligent manufacturing solutions for 

aerospace, energy, electric vehicles and biomedical industries. 

It also presented automation technology, multi-axis machining, 

additive manufacturing, factory monitoring, digital 

twins and other exciting highlights. TTGroup is committed 

to digital and green transformation to help customers build 

their competitiveness in the future. 

TONGTAI 

Starting as a specialized machine manufacturer, TONGTAI 

celebrates 2024 its 55 th year and has become the leading machine 

tool manufacturer with the most extensive product line 

in Taiwan. Continuing the company’s central axis of development 

through the concept of “intelligence, automation, 

hybrid, net zero, servitization, new industries and new processes” 

and introducing seven solutions, the company has 

initiated a two-axis transformation plan of digital and green 

transformation. It is firmly moving forward toward the 

goal of building an intelligent ecosystem of machine tools. 

Tongtai displayed three machines during TMTS 2024, including 

the MT-1500 parallel dual-spindle dual-turret CNC 

lathe, the HTT-500 horizontal 5-axis machining center and 

the VP-12 vertical machining center. The MT-1500 integrates 

a loading and unloading robot, dual spindles, and dual turrets 

for simultaneous machining. The design doubles production 

efficiency and provides a perfect solution for the machining 

industry’s workforce shortage. The MT series features a 

smaller footprint, short travel distances, minimal idle time 

and minimal thermal displacement. The TiOperator software 

enables the MT series to achieve efficient 24-hour operation 

effortlessly. 

The HTT-500 is the latest intensive production solution. 

It has an intelligent chip flushing system and an APC (auto 

pallet changer) system. It can also measure and compensate 

for spatial accuracy, solving the customer’s difficulties in 

five-face machining. In contrast the VP-12 is the individual 

machine with the robot and AGV transportation that enables 

unmanned material replenishment, meeting the demand 

for high efficiency and precision machining. In recent years 

Tongtai has developed various intelligent software to help 

the operator grasp the data during machining by utilizing 

the machine and multiple sensors. It has a friendly operator 

interface, making production management more intuitive. 


49

TMTS 

HONOR SEIKI 

HONOR SEIKI is dedicated to large component machining 

for energy industries with intelligent vertical lathe solutions. 

Utilizing “Hard turning” technology for process integration 

of slewing bearings significantly enhances the customers’ 

production efficiency by over 20 %. Honor Seiki’s wind power 

solution has expanded up to 6 m vertical lathes, suitable for 

machining large-scale castings, thus contributing to the 

localization of Taiwan’s wind industry. Furthermore Honor 

Seiki has achieved significant progress in the clean energy 

sector, particularly in hydrogen energy industry processing. 

The company has successfully entered the European market, 

collaborating with key customers to enhance automation and 

intelligence processes and thereby improve product value 

and services. This collaboration also enhances customer processing 

and production efficiency, resulting in a mutually 

beneficial outcome. 

APEC 

Asia Pacific Elite Corp. (APEC) has cultivated the aerospace 

market for nearly 20 years. APEC takes “Aiming at aerospace 

solutions” as the brand’s core spirit and provides excellent 

application support and customized solutions to high-end 

customers. The company presented its latest development at 

TMTS, the 5-axis milling-turning machining center G800T. 

This machine features a compact body size, combining 

milling and turning processes, providing a new solution for 

small-scale precision machining. The vertical structure of 

the G800T breaks through the limitations of traditional lathe 

processing, allowing for smoother transitions from turning 

to milling without the need to move the workpiece, thus 

reducing processing time and human errors. Customers can 

efficiently complete tasks without switching processing workflows, 

enjoying a more modern machining experience. 

Quick-TECH 

Quick-TECH presented the i-42 Ultimate multi-tasking turning 

center, the best engineering-intensive solution, which is 

particularly suitable for the medical biotechnology industry. 

Various medical-related parts such as spinal components, 

medical screws, hip joint components and cervical 

bone plates can be manufactured by this machine. It features 

24 milling tools and 25 turning tools, a dual-program, twin 

spindles operating system. Its multi-axis compound turning 

and milling capabilities allow for completing complex 

part processing in one machine, enabling fully automated 

processing and significant time savings. QuickTECH 

provides efficient medical-grade complex parts processing solutions, 

enhancing overall production efficiency and quality. 

FFG/Feeler 

Fair Friend Group (FFG) was established in 1979 and started 

the business as the agent of Japanese KOBELCO construction 

machinery. FEELER, the original machine tool division of 

FFG was established 1985. The main products during its beginning 

were band sawing machines and grinding machines. 

Realizing the industry trend toward high automation and 

unmanned operations in the machine tool industry, FEELER 

invested in the development of advanced CNC machine tool 

products. In 1986 FEELER built the frist moving column vertical 

machining center in Taiwan and it was highly regarded 

by the market. In the same year the company was officially 

transformed into a professional CNC tooling machine manu - 

facturer and marketed its products worldwide under the 

FEELER brand. The main products include vertical and horizontal 

machining centers, vertical and horizontal lathes, 

5-axis, automated production lines, etc. 

Unmatched performance 

The U-600P 5-axis machining center is designed specifically 

for high-speed and high-precision machining, with high rigid - 

ity of the machine structure, and its 3-axis (overlapping) and 

2-axis rotary axes are separated, to avoid the accumulation 

of Abbe error caused by the rotary “curvature error” and the 

3-axis “movement error”. Easy error compensation ensures 

excellent cutting accuracy. 

The three-axis structure of the machine stacked above 

the base provides a large processing space, which allows the 

operator to observe the processing and milling process 

more easily and clearly, and effectively improves the 

lifting and loading of large workpieces. Box-structure 

casting and optimal span stand for exceptional rigidity and 

stability. 

High speed and high quality 

FEELER VUX series 4/5-axis vertical machining center solve 

the axial limitation of 3-axis machining and satisfy the needs 

for machining products with special angles and complex 

multi-curved workpieces. The machine is equipped with an 

automated loading station and multi-drawer design, which 

allows flexible workpiece configurations without limiting the 

machining of a single type of workpiece as the automated design 

significantly improves production efficiency. 

The automatic loading system is designed to load the material 

without stopping the machine, the material station can 

be dragged in both directions, and while the robot is operating, 

the operator can work on the other side to collect the 

finished product and place the unfinished product, which increases 

the efficiency. The re-calibration of the workpiece is 

omitted when working by robotic operation. 

further information: www.tmts.tw 


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Adelbert Haas GmbH ................31 

ANCA Pty LTD .............. 20, 21, 44 

Asia Pacific Elite Corp. (APEC). .......50 

Aurion Machining Technologies .......31 

CemeCon AG .......................12 

CERATIZIT ........................16 

CloudNC. ..........................45 

ECTA – 

European Cutting Tools Assocation ..18 

EMAG GmbH & Co. KG ..............36 

Fair Friend Group (FFG)/Feeler. .......50 

FILL Gesellschaft m.b.H. .............37 

fives Group ........................ 40 

Fritz Studer AG .................... 42 

Gräbener Maschinentechnik 

GmbH & Co. KG ..................34 

GrindingHub .......................27 

HaiNan Neocrystech Co., Ltd. . ........10 

Hartmetall-Werkzeugfabrik 

Paul Horn GmbH ................ 6, 9 

company finder 

HONOR SEIKI CO., LTD.. ............50 

KAPP GmbH & Co. KG. . ......... 18, 28 

Lach Diamant Jakob Lach 

GmbH & Co. KG ................ 8, 22 

Leitz GmbH & Co. KG . ..............14 

Licon mt GmbH & Co. KG. ...........38 

Liebherr Verzahntechnik GmbH . .....32 

ModuleWorks GmbH ................19 

Platinum Tooling Technologies, Inc ....19 

Quick-TECH Machinery Co., Ltd. .....50 

SBS ECOCLEAN GROUP ........... 46 

TIGRA GmbH ......................14 

TMTS ..............................47 

TONGTAI 

MACHINE & TOOL CO., LTD. ......49 

TTGroup ...........................49 

UNITED GRINDING Group ........ 42 

Vomat GmbH. ......................43 

YCM. ..............................49 

VAT DE 133 510 873 

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to copyright law. Any use without the 

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copyright © 2024 Dr. Harnisch Publications 

advertising index 

ANCA Pty LTD ........................................................page 15 

Günther Effgen GmbH ..................................................page 9 

Hartmetall-Werkzeugfabrik Paul Horn GmbH ..........................front cover 

Lach Diamant Jakob Lach GmbH & Co. KG ....................... inside front cover 

Liebherr Verzahntechnik GmbH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11 

SPR ABRASIVES CORP. ................................................page 13 

VDW Verein Deutscher Werkzeugmaschinenfabriken e.V ...................page 3 


51

GREEN EFFICIENT TECHNOLOGIES 

The independent media platform for 

energy supply, efficiency enhancement and 

alternative energy sources and storage 

Sustainable opportunities in process 

technology 

Circular economy in the industrial 

production process 

Topics H 2 

, Synthetic Fuels, Water, 

Solar & Photovoltaics, Wind Power, 

Bioenergy, Geothermal Energy, Battery 

Technology, System Integration and 

other alternative options 

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