hpt 2025 #1

ISSN 2628-5444
high precision tooling
Machine Tools, PCD, PVD, CVD, CBN, Hard Metal 2025 – 1
»IC-plus« (pat.)
Chipbreaker
... a must-have for turning aluminium
® ®
www.lach-diamant.de · office@lach-diamant.de
■ Special threading tools for performance in space ■ Experiencing of what the future of metalworking is holding ■
■ Mastering technical ceramics ■ For more efficient production ■

More than tools
innovations
THREE NEW CRAZY
HIGH-PERFORMANCE CUTTING TOOLS
www.mikrontool.com

editorial
Eric Schäfer
editor-in-chief
Maybe it’s only half as bad?
Negative scenarios continue to dominate the economic
news and even the major business associations are not
really spreading optimism. Supply chain problems, rising
commodity prices and geopolitical tensions are weighing on
the global economy. Despite periods of weakness in the key
export markets of the US and China, declining incoming
orders, an unclear economic policy course in the EU and
a currently weak automotive industry, the major autumn
trade fairs AMB in Stuttgart, IMTS in Chicago and JIMTOF
in Tokyo recorded extremely lively visitor interest. This
was particularly noticeable at JIMTOF in Japan. The rush
of visitors to the impressive Tokyo Exhibition Center was
a proof to curiosity about current and future technologies,
new solutions and developments in the field of metalworking.
The trending topics of automation and digitalization are
driving growth and opening up new business opportunities.
Decarbonization is giving new impetus to the industry
and promoting sustainable business practices. The use of
digital technologies such as 3D modelling and simulation
technology optimizes processes and reduces manufacturing
costs. Find out more in our trade fair review of JIMTOF 2024.
In addition, sectors such as aerospace, wind and solar energy
and electronics are developing dynamically and require
investments for increasing demand for state-of-the-art
manufacturing technology.
Eric Schäfer
editor-in-chief
Curious about this? Continue reading page 28…
no. 1, March 2025
3

table of contents
cover story
How super-abrasives conquered the world
written by Horst Lach 6
materials & tools
Three new “crazy” high-performance tools 10
Special threading tools for performance in space
written by Dr. Peter Schniering 16
Precision solutions for metalworking 19
Engineered in record time 21
processes
Mastering technical ceramics: precision ductile CNC machining 34
machining center
HoverLIGHT: unique damping for machine tools 36
For more efficient production 38
Designed for production 40
Double the power for machining large light metal workpieces 42
Precision manufacturing of high performance transmission components on
vertical pick-up turning machines 44
components
Superior performance on 5-axes 45
ModuleWorks releases 2024.12 software components 46
More value from coolant 48
Digital technologies for efficient automation at every level 49
Production of transmission parts for electric cars 50
news & facts 23
fairs 5, 27
JIMTOF 2024 28
impressum & company finder 51
4 no. 1, March 2025

fairs in alphabetical order
CIMT Beijing, China
(April 21-26, 2025)
CMTS Toronto, Canada
(Sept 29-Oct 2, 2025)
EMO Hanover, Germany
(September 22-26, 2025)
EPHJ Geneva, Switzerland
(June 3-6, 2025)
current status
2025
2025
2025
2025
FEIMEC Sao Paulo, Brazil
(May 5-9, 2026)
intec Leipzig, Germany
(March 11-14, 2025)
Hannover fair Hanover, Germany
(March 31 - April 4, 2025)
2025
2025
2026
HI Tech & Industry Herning,
Scandinavia (Sept 30-Oct 2, 2025)
Denmark
2025
IMT Brno, Czech Republic
(October 7-10, 2025)
LIGNA Hanover, Germany
(May 26-30, 2025)
MACH-TECH and Budapest, Hungary
INDUSTRY DAYS (May 13-16, 2025)
METALEX Bangkok, Thailand
(November 19-22, 2025)
MOULDING Stuttgart, Germany
EXPO (May 6-9, 2025)
2025
2025
2025
2025
2025
NORTEC Hamburg, Germany
(February 3-5, 2026)
2026
PARTS FINISHING Karlsruhe,
DeburringEXPO (November 12-13, 2025)
Germany
2025
SIAMS Moutier, Switzerland
(April 21-24, 2026)
SIMTOS Seoul, South Korea
(April, 2026)
2026
2026
sps Nuremberg, Germany
(November 25-27, 2025)
2025
SteelFab Sharjah, United Arab
2026 (January 12-15, 2026) Emirates
2026
TIMTOS Taipei, Taiwan
(March 3-8, 2025)
2025
TMTS Taichung, Taiwan
(March 3-7, 2026)
2026
trade fair dates as by end of February 2025; we are not responsible for reliability of these dates
no. 1, March 2025
5

cover story
How super-abrasives conquered the world
Horst Lach
…has been known for over six decades as an innovator in the development
of diamond tools for the industry and is absolutely recognised as a pioneer.
Still, at the age of 85, he is working
for his company LACH DIAMANT ® every day.
As a highly esteemed author of our magazines “dihw” and “hp tooling”,
Horst Lach has created two series: “Poly-poly” and
“100 years of Lach Diamant”. In these he describes the paths
into a new era of material processing with PCD, CBN etc. all the way
to the latest applications.
We would like to congratulate our author and look back with him
to his start at his father’s company.
Horst Lach, born in 1940, manages LACH DIAMANT®
together with his son, degreed engineer Robert Lach;
the company was founded by Jakob Lach in 1922
The first company outing of the diamond grindery Jakob Lach in 1924.
The founder of the company, Jakob Lach, is sitting at the right side.
Does LACH DIAMANT present 117 years of expertise and know-how?
Actually, the company was founded only 103 years
ago, but as the founder’s son, Horst Lach, recalls “the
acquirement of knowledge began already in 1908 when
Jakob Lach started his apprenticeship as a diamond cutter.”
When wage grinding became unprofitable after
World War II, Jakob Lach focused on his second company,
which he had founded in the 1930’s for the sale and
distribution of industrial diamonds. “Jakob Lach –
Industrial Diamonds” [Deutscher Industriediamanten-
Vertrieb Jakob Lach] was very successful in the Magdeburg –
Leipzig – Chemnitz area (Germany) and well known
among automobile manufacturing companies such as
Opel in Rüsselsheim (Germany).
6 no. 1, March 2025

cover story
1969 – the very first BORAZON TM CBN presentation worldwide
1973 – the starting point of the first success story due to PCD –
more efficient copper collector machining
With this, a new era had begun for the Jakob Lach company
– the name LACH DIAMANT® was born. Dressing and
profiling of grinding wheels with industrial diamonds (both
set and rough self-imported diamonds) became the primary
business of LACH DIAMANT in the 1950’s.
Abrasives of a new age
After Horst Lach joined LACH DIAMANT® on October 1 st ,
1960, the company started manufacturing diamond grinding
wheels in metal and resin bond for the grinding of hard
metals and ceramics. “The development of metal-coated
diamond grits by DeBeers (for example grit type RDA-MC)
was instrumental, not only for the success of diamond
grinding wheels in resin bond for carbide processing (e. g.
LACH DIAMANT®’s grinding wheel K-MC) but also for the
development of carbide tools in general”, Horst Lach recollects.
“At the same time this paved the way for the commercial
success of tool manufacturers such as Leitz, Leuco,
Sandvik, Widia and grinding machine manufacturers like
Vollmer – Dornhan or Biberach, Walter, Stehle and other companies
like them”.
General Electric (GE), a manufacturer of super-abrasives,
set another milestone with its introduction of Borazon TM
(boron nitride – CBN), a modern day abrasive. “Finally it
was possible for tool grinders to accomplish precise circular
grinding of HSS milling tools on a Deckel grinder in a
one-step process – without having to continuously find new
measuring points on a traditional corundum grinding wheel”,
Lach comments.
The higher temperature resistance of the new abrasive
Borazon TM -CBN (up to 1500 ° C) compared to diamond (up to
720 ° C) made this possible despite a low degree of hardness.
The new material revolutionized the industry, and its potential
for future processes and applications has still not been
fully realized. It is a new material with a great deal of potential
for future developments, processing, and applications for
the grinding industry, as the presentations at GrindTec demonstrate.
LACH DIAMANT® introduced the new “supergrind-power”
grinding wheel and “drebojet®-plus”.
At the beginning of the 1970’s everything in the world of
tool manufacturers appeared to be “just fine”, as Horst Lach
remembers, until two new product innovations by GE shook
the industry. These were PCD, a polycrystalline cutting
material first introduced in 1973, and in 1974 CBN and PCBn,
another polycrystalline cutting materials.
Historically interesting is the fact that GE researchers came
across cubic crystalline boron nitride (CBN) early on, during
their search for diamond synthesis. However, at that time
they did not know what to do with this material since it had
such a low hardness compared with diamonds.
Horst Lach remembers that Carboloy in Frankfurt, a GE
company, already had CBN blanks in storage during the early
1960’s. Later these blanks were marketed as BZN blanks.
LACH DIAMANT® has been a pioneer from the very
beginning – as a matter of fact since the first development,
production and commercialization of Borazon TM CBN grinding
wheels. “We demonstrated turning of aluminum with interrupted
cuts with a new cutting material PCD – dreborid® –
at the Hanover Trade Show in 1973. GE offered polycrystalline
synthetic diamond segments with 600 and 900 angles for
the first time in 1973. At the time it was very difficult to cut
them out of blanks with only 0 3,4 mm, and cutting lengths
were equally limited”.
1973 –
for the very
first time, GE offers
polycrystalline diamonds for tool manufacturing
no. 1, March 2025
7

cover story
Beastly materials
Grinding these polycrystalline materials
was also problematic; diamond cutters, used
to grinding natural diamonds, called them
“beastly materials” without any structure
and they rejected them. LACH DIAMANT®
was able to produce the very first PCD lateral
turning tool on an existing Simon tool
grinding machine with a diamond cup
wheel in resin bond (K-MC, 125x12.5) – just
in time for the Hanover Trade Show in
spring 1973.
“We had a Weiler turning machine with a
clamped-on aluminum round part for the following
demonstrations. It was covered with
bores in order to simulate interrupted cutting.
Without knowing an exact tool life, we had
ordered one replacement tool per show day
(10 days at the time!) from our manufacturing
facility in Hanau.
After three days we called off the special
driver who transported the tools to Hanover;
the PCD cutting edge worked and worked
and worked, and at the time we believed we
could never wear it down. We only accomplished
that on the very last day of the show,
when we boisterously placed a small bottle of
sparkling wine into the machine... that was
the starting point of PCD and the legendary
dreborid® at LACH DIAMANT”, describes
Horst Lach with a smirk.
1974 – LACH DIAMOND® demonstrates for the first time the milling of
plastics and aluminum with PCD at the Hanover spring trade show
(image shows machining of GRP)
LACH DIAMANT® had decades of experience
in manufacturing and servicing natural
diamonds for the manufacturing companies
of copper collectors for the electrical industry,
and therefore the company focused at first
on those customers, such as Bosch, Siemens,
AEG and this strategy proved to be very
successful.
“Until then a natural diamond tool for collectors
could turn between 100 and 120,000
collectors at the most. PCD dreborid® turning
tool made much more economically sound
numbers possible. Today, depending on collector
size and cut, one tool can produce up to
220,000 collectors. Truly electrifying results
were achieved when PCD dreborid® was tried
out at Kautt & Bux, a manufacturer of rough
collectors. Until then rough collectors had to
be ground in a time-consuming process. Now
this procedure could be done in a few seconds
by turning instead of grinding the collectors
for several minutes. This meant for LACH
DIAMANT® that they had won a key account
customer right from the get-go. Both, PCD
manufacturing and service could be built on
this initial success.
1977 – at productronica, Munich, the worldwide first presentation of
PCD milling cutters, saws and scoring saws for machining abrasive plastics
Alternatives on the market for grinding machines
Even diamond cutters of natural diamonds had surrendered to the “beastly”
polycrystalline cutting material PCD. New procedures had to be developed
and at least some alternative solutions were needed on the market for grinding
machines.
“Quick decisions were of the essence, since from the very beginning, there
were a lot of potential users of PCD, including machining companies who
processed aluminum, hard and soft plastics, wooden materials, green
ceramics and other materials; the optimal grinding system should not only
accomplish straight edges but should also be able to grind angle and radius.
The final choice was a rather ‘delicate’, yet extremely precise, tool grinding
machine, the Kelch SZ34”. LACH DIAMANT® and the manufacturer from
8 no. 1, March 2025

cover story
Southern Germany worked closely together in order to adapt the machine
specifically to PCD grinding. After the production license was transferred,
LACH DIAMANT® continued to build this machine under the new names
“pcd-100” (equipped with swivel part) and “pcd-300” (equipped with optional
adjustable spherical head). Requests to produce PCD-tipped rotating tools
such as milling cutters, scoring saws and saws were fulfilled at productronica
in Munich in 1977. LACH DIAMANT® had chosen GRP (glass fiber enforced
plastic), an extremely hard-to-machine material for this “trial run of
PCD-tipped rotating tools”. GRP is used as base material (PCB) in the production
of circuit boards. 35 hours of grinding time for twelve teeth was
accepted in the false hope that “we would eventually find something better”.
Not at all. With the grinding technology of the time, there was no reduction
possible. The initial enthusiasm of the exhibition visitors quickly gave
way to accusations of withholding these cost-cutting miracle tools. Potential
customers held this grudge for years.
Machining of composite materials
In 1978, one and a half years after this rocky start, a memory triggered
another brilliant idea. Horst Lach remembered the words of his father that
“electricity has a major part in grinding diamonds (he was talking about
natural diamonds)”. Horst Lach was reading an advertisement for Fanuc
erosion machines of the former company Matra.
“The reader should know that at the time GE and supplier DeBeers still
used electro-plated diamond cutting wheels for cutting PCD blanks: the
back of the hard metal surface of up to 6.4 mm round PCD blanks was first
scored, then broken. At that time spark erosion had not yet been discovered”.
His interest was piqued.
A visit to Matra would change the world of machining. After a first successful
attempt to machine and form the electro-conductive PCD via
spark erosion, this new process opened up the same possibilities for PCD
which hard metals had finally established over HSS and ceramics. LACH
DIAMANT® entered the market of machining wood and composite materials
by founding LACH-SPEZIAL-WERKZEUGE GmbH which in turn established
LACH DIAMOND® INC. for the American and Canadian markets.
A very bright future
PCD diamond tools proved to be 250-300 times as efficient as hard metaltipped
woodworking tools. NC manufacturing technology was soon developed
into CNC technology with multi-axis machines. “Today we know that
this technology did not stop at metal machining. All the advancements of
today’s automobile, aircraft, energy (especially wind energy with CFRP
wings), sports and medical industries – to name only a few – would not have
been possible without diamond, without polycrystalline synthetic cutting
materials, including so-called mono diamonds and CVD (chemical vapour
deposition)”. After the development of spark erosion, or electrical discharge
machining, Horst Lach obtained one of the first European patents. He withdrew
the patent voluntarily after a Swedish tool manufacturer lodged an
appeal. This discovery opened up a vision of a very bright future. Continuous
innovations have proven this up to this day. LACH
DIAMANT®’s entrepreneurial success with erosion
technology is particularly evident in its technologically
mature, well-engineered erosion grinder,
Dia-2200-mini”, which machines diamond tools
for the wood and plastics industry. With its extensive
portfolio LACH DIAMANT® stands at the
cutting edge of machining and grinding technology
(Future for Today).
Horst Lach
further information: www.lach-diamond.com
1978 – Horst Lach’s discovery of spark erosion
made everything possible, example: production of
multiple diamond saws on LACH DIAMANT®’s
universal sharpening machine “Dia-2200-mini”
2016 – GrindTec Augsburg: introduction of
“drebojet®-plus” as another example of non-stop
innovations; contour-controlled dressing of
conventional grinding wheels at
LACH DIAMANT®’s booth
no. 1, March 2025
9

materials & tools
Three new “crazy” high-performance tools
Mikron Tool – the global leader in the machining
of difficult-to-machine materials in the micro range –
presents three new solid carbide tools. A high-performance
drill for all types of titanium and two
high-performance milling cutters tailored to filigree
components. With these three new developments,
Mikron Tool is setting benchmarks in high-performance
micro-machining.
particular attention to this. And the range of possible materials
that can be machined with the new milling cutters, has
increased considerably; more on this below.
The “madmen from Agno” have gone full throttle again:
CrazyDrill Titanium TN/TK, CrazyMill Cool CF and
CrazyMill Cool SF are the latest high-performance microtools
from the Swiss-based tool manufacturer Mikron Tool,
which has set benchmarks in the micromachining of difficultto-cut
materials over the last 25 years and won several industry
awards for its high-performance microtools.
Titanium, chromium-nickel steels, cobalt-chromium
and Inconel & Co
The tool specialists from Switzerland consistently focus
on two key factors in their new tool developments: Firstly,
maximum productivity with – secondly – very long tool life,
focused on the micro-manufacturing sector in the machining
of high-performance materials such as titanium, chro miumnickel
steels, cobalt-chromium or high-temperature alloys
such as Inconel. These materials are typically used in medical
technology, watchmaking, aviation, the automotive industry
and the chemical industry.
In addition, the focus is on aspects such as the required
surface quality and precision on the workpiece over the entire
service life of the tools. Speaking of surface quality, the
two high-performance milling cutters CrazyMill Cool CF
(Chatter free) and CrazyMill Cool SF– (Super Finishing) pay
The CrazyDrill Titanium TN/TK micro drill for drilling all
titanium alloys including pure titanium (!) for the diameter
range from 0.2 to 2 mm and for drilling depths of 3 x d and 6 x d;
especially for production conditions that are designed
without high-pressure cooling lubricant systems
10 no. 1, March 2025

materials & tools
CrazyDrill Cool TK/TN: cutting geometry
CrazyDrill Titanium TN/TK –
high-performance micro drills for titanium
The CrazyDrill Titanium TN/TK micro drill has been specially
developed for drilling all titanium alloys (!) including
pure titanium (!) for the diameter range from 0.2 - 2 mm and
for drilling depths of 3 x d and 6 x d. The TK version can already
be used from 15 bar internal cooling, so a high-pressure
cooling lubricant system is not absolutely necessary. Whereas
the TN version was developed for external cooling.
Alberto Gotti (head of development, Mikron Tool): “We
have designed both the micro and macro geometries of the
CrazyDrill Titanium TN/TK in such a way that it generates
high performance for all titanium materials. This is anything
but easy, as the machining behavior of titanium alloys differs
relatively greatly from one another. Nevertheless, there are
similarities in the machining behavior of titanium alloys.
This is exactly where we started with the development of the
CrazyDrill Titanium TN/TK.”
Critical machining behavior of titanium
An example: when drilling titanium, it is critical that the edge
zones in the cutting area deform elastically during machining,
so to speak, avoiding the cutting edge of the tool, causing the
diameter to taper again during the drilling process, which
can typically lead to an increase in torque and, in the worst
case, to the drill breaking.
Alberto Gotti: “This knowledge is crucial for the development
of the micro and macro geometries of the drills, which
must be tailored to this material behavior so that the holes
can be drilled reliably.”
Titanium machining: high energy and heat input
Another common feature of all titanium alloys is the high
energy input required to machine titanium, which ultimately
leads to a high heat input in the cutting zone at the main cutting
edges, which in the case of titanium can only be dissipated
insufficiently via the chips, because of the poor thermal conductivity
of titanium. Excessively high temperatures at the
cutting edges lead to micro-chipping and faster tool wear.
The solution here is to cool, cool, cool and/or use carbide
substrates that have a higher heat resistance. In addition, it
is crucial to choose a high-performance coating that protects
the carbide substrate from excessive heat input.
When it comes to cooling, Mikron Tool relies on its patented
cooling system integrated into the shank, whose kidneyshaped
cooling channels provide highly efficient and targeted
cooling from a coolant pressure of just 15 bar and ensure
reliable chip removal.
The above-mentioned aspects were fully taken into account
in the design of the CrazyDrill Titanium TN/TK micro drill.
CrazyDrill Cool TK/TN: positional accuracy
no. 1, March 2025
11

materials & tools
CrazyDrill Cool TK/TN: high hole precision
The new CrazyDrill Titanium TN/TK micro drills are
characterized by the following design features:
■ a tip geometry tailored to titanium alloys
■ an outer drill profile specifically designed
for titanium drilling
■ polished flutes for safe chip transportation
■ a coating specially designed for titanium materials
and drilling
This means that the CrazyDrill Titanium TN/TK high-performance
drill is capable of drilling all titanium alloys as well
as pure titanium with process reliability. The CrazyDrill Titanium
TN/TK delivers maximum feed rates, very long tool life,
optimum process reliability and ultimately very high drilling
precision. It extends the CrazyDrill Cool Titanium ATC/PTC
titanium drill series launched last year.
The high-performance CrazyMill Cool CF micro milling
cutter is designed for a very high metal removal rate,
and its performance can also be utilized for
filigree component structures
High-performance milling with outstanding
surface finishes up to grinding quality
Two new high-performance milling cutters have been
devel oped in the milling area. The first is the CrazyMill Cool
CF and the super finishing milling cutter CrazyMill Cool SF.
One of the main objectives in the development of these
milling cutters was to mill the milled surface finish to an extremely
high quality for applications in the medical, aerospace
and watchmaking sectors, where delicate components
are the order of the day.
CrazyMill Cool CF: avoidance of resonance frequencies
12 no. 1, March 2025

materials & tools
CrazyMill Cool CF: traditional milling versus High-Efficiency Milling (HEM)
CrazyMill Cool CF: shaft cooling
Both milling cutters were developed with specifically
designed macro and micro geometries that consistently
suppress vibrations in the manufacturing process. The main
cutting edges were designed in such a way that they have an
extremely soft cut. But that’s not all. In order to consistently
avoid resonance frequencies in the milling process, both
CrazyMill Cool CF and SF high performance milling cutters
have unequal teeth division. In addition, the individual cutting
edges have different helix angles.
Alberto Gotti: “In the case of delicate components such
as bone plates, watch components or aerospace components
with narrow, projecting webs, resonance frequencies can
occur during the milling process and massively hinder the
milling process.”
“To ensure that no resonance frequencies occur during the
milling process, we have to integrate an asymmetry into the
milling cutter geometry that prevents resonances. To do this,
we use mathematical models to determine the ideal pitch
angles and the variable helix angles of the cutting edges.
Ultimately, however, our production department must also
be able to grind the complex geometries in series.”
CrazyMill Cool CF: high-performance milling
of filigree components
The CrazyMill Cool CF is a high-performance micro milling
cutter designed for a very high metal removal rate whose performance
can also be called upon for very demanding filigree
component structures. Including generation of outstanding
surfaces without chatter marks. To achieve such results, the
latest generation of milling cutters works with the lowest
cutting pressures and completely vibration-free.
With its specific cutting geometry and using a dynamic
milling process, it is the ideal milling cutter for delicate, thinwalled
parts or for parts in unstable clamping, which is particu -
larly common in the medical technology sector (bone
plates) and aerospace (structural components) as well as the
watch industry. However, CrazyMill Cool CF also carries
out grooves, pockets or other high-volume machining
operations very efficiently, precisely and with extremely
smooth running.
The milling cutter is now available in diameters ranging
from 1 - 8 mm in two different full cutting lengths (3 x and
4 x d).
no. 1, March 2025
13

materials & tools
CrazyMill Cool SF
CrazyMill Cool SF: applications in the watchmaking industry
The CrazyMill Cool SF is a superfinishing
milling cutter that has been developed to
bring milled surfaces to a grinding
respectively polishing quality level
The steep helix angle of the
CrazyMill Cool SF significantly
reduces the radial cutting forces;
whereas the axial cutting forces
increase, which has a beneficial
effect on the resulting cutting
forces and leads to an extremely
smooth cut and excellent surfaces
CrazyMill Cool SF – superfinishing
up to Ra 0.2 µm
This superfinishing milling cutter was developed
to bring milling surfaces to a grinding
or polishing quality level. It was also designed
with the macro geometries described
above, and has a very steep helix angle.
Alberto Cotti: “The steep helix angle significantly
reduces the radial cutting forces.
The axial cutting forces, on the other hand, increase,
which has a positive effect on the resul
ting cutting forces acting on the workpiece
and also on the deflection of the milling cutter,
resulting in a smooth cut. The result is an extremely
smooth milling process, practically vibration-free.
We achieve surfaces with a rough -
ness of less than Ra 0.3, measured parallel
and perpendicular to the milling direction.
That is sensational. For the user, this means
that subsequent finishing processes, such as
grinding or polishing, are either completely
eliminated or require considerably less effort.”
The CrazyMill Cool SF is available in the
diameter range from 1 – 8 mm and in two full
cutting lengths of 3 x d and 4 x d. This new
super finishing cutter has the perfect ingredients
to achieve an amazing surface quality:
the carbide substrate, the highly efficient cooling
concept, the perfect cutting-edge treatment,
the variable helix angle, the unequal
teeth division, etc.
Extremely smooth
milling behavior
Due to the extremely smooth
milling behavior of the two
high-performance milling
cutters, the tool life has increased
massively compared
to the benchmark. Alberto
Gotti: “With the CrazyMill Cool CF, a very high metal removal rate can
be generated, and an excellent surface finish can be achieved on the workpiece
at the same time. The CrazyMill Cool SF is designed as a finishing
cutter, where our focus is on the fastest possible surface finishing. Here too,
the extremely smooth, vibration-free milling process results in an enormous
increase in tool life compared to conventionally designed milling cutter
geometries.
Also for brass, copper, cobalt-chrome and Inconel
The first tests at the Mikron Tool Technology Center showed that the
CrazyMill Cool SF also generates excellent surface finishes in lead-free brass,
copper, cobalt-chrome and Inconel. Ra values below 0.3 µm were achieved
with the CrazyMill Cool SF for all the above materials. Simply crazy.
For special customer requirements: The new
tools/technologies can also be requested and
ordered as customer-specific variants.
Video of the new milling cutters
further information: www.mikrontool.com
14 no. 1, March 2025

New tools for deep axial grooving
materials & tools
The new Mini 114 system from Horn enables a face grooving
depth of up to 10 mm. The Tübingen-based tool manufacturer is
thus further expanding the already wide variety of this product
family. The insert is suitable for turning and copy turning of axial
grooves.
Face grooving to
a depth of up to
10 mm is possible
with the new
Mini 114 system
(foto HORN/
Sauermann)
The user does not need a special tool holder, as the insert is compatible with
the existing axial holder system. As standard Horn offers the EG55 carbide
grade grooving tools in three different types from stock with cutting widths
of 2 mm, 2.5 mm and 3 mm. The minimum diameter for grooving is 14 mm,
while the maximum is 34 mm – 36 mm, depending on the type.
The face-screwed inserts of the Mini system are one of Horn’s core products.
The tool system is suitable for turning and milling applications. The
precision tools have proven particularly effective for boring, internal grooving
and face grooving. Paired with the low-vibration carbide tool holders,
the inserts produce good surface finish even with long overhangs and ensure
excellent process reliability. The Mini system’s broad portfolio offers inserts
in various sizes for different internal diameters as well as different geometries
and substrates and CBN or diamond tips.
further information: www.horn-group.com
High performance over a long period
The introduction of 3M Cubitron
3 High- Performance abrasives marks a
sig nificant step forward in the manufacturing
industry. The technology, a result
of extensive research and development,
will fundamentally change the way
companies worldwide conduct grinding
operations.
In a time of change and increasing demands
in the manu facturing landscape, the pursuit
of excellence is crucial. The introduction of
3M Cubitron 3 fiber discs, grinding wheels,
and cloth belts makes grinding processes
faster, more efficient, and safer. Through
patented breakthroughs in abrasive grain
shape and molecular bonding techno logy,
this new product line delivers exceptional
performance levels.
Thanks to a significantly higher cutting
speed companies can process more parts
with fewer resources, leading to increased
productivity. For example, 3M Cubitron
3 fiber disc 1182C delivers up to 61 % faster
cut rate compared to previous generation
3M Cubitron II fiber disc 982C. Also the
disc lasts longer than conventional competitor products: up to 34 % more material
can be removed compared to a conventional fiber disc. 3M Cubitron
3 Cut-off wheels last up to 3X longer compared to previous generation 3M
Cubitron II Cut-off wheels. This means more parts can be processed with
fewer disc changeouts needed and less downtime.
Durable and sustainable
The development of 3M Cubitron 3 High-Performance Abrasives also took
into account the increasing automation, which helps to maximize the efficiency
of automated manu facturing processes. The durable abrasives and
packaging with recycled materials meet the industry’s sustainability goals
and help reduce the ecological footprint. By combining engineered abrasives,
processes can be streamlined faster and easier across all steps involved. With
breadth of solutions, winning combinations can involve any abrasive pairing
tailored for specific process requirements to deliver superior results, reduce
process times, and improve overall productivity.
further information: www.3m.com
no. 1, March 2025
15

materials & tools
Special threading tools for performance in space
written by Dr. Peter Schniering
High end application small satellites in low earth orbits
Manufacturing threading tools for aerospace
components represents a significant challenge for the
machining industry. The focus is on crafting application-specific
geometries and adhering to extremely
tight tolerances when working with highly alloyed
specialty steels.
Manufacturers of precision tools are accustomed to creating
products capable of machining high-precision components.
These components demand threads for motion and fastening
that must meet extreme tolerances on the edge of technical
feasibility. Fields like motorsports, turbine construction and
medical technology continually introduce new materials, impose
strict dimensional accuracy requirements and demand
close to 100 % process reliability. But the demands for threading
applications in aerospace far exceed those of terrestrial
high-end industries.
The business in space:
a high-growth market in transition
In recent years the market for space components, especially
for satellites, has developed dynamically. While composite
materials are being used increasingly, machining is also on
the rise. In Europe the market for aerospace composites alone
is expected to grow by an average of almost 10 % until 2028.
Manufacturers of aerospace components are demanding ever
more cost-efficient and faster production. Another important
aspect is increasing miniaturization and the increased use of
small satellites in low earth orbits. Modern small and lightweight
satellites require high-performance connection and
cabling systems that are technologically flexible and enable
high data transmission rates. The market for space components
is facing a phase of high growth due to technological
innovations, the introduction of new materials and production
techniques and the increasing demand for smaller
satellites. Machining in general, and threading in particular,
are highly demanding fields.
The journey into space: a challenge for threads
One major reason for these extreme demands is the operational
environment. In orbit threads are positioned
up to 36,000 km from earth, moving at speeds exceeding
11,000 km/h. No possibility for post-processing or maintenance
exists; the threads must perform flawlessly to prevent
system failures, such as the malfunction of an entire satellite.
Automated measuring system for the space taps from Zoller
To commission components in a geostationary orbit or a
low-earth orbit (starting around 200 km altitude), they must
first endure significant stress during transport via rocket,
including intense vibrations and G-forces up to ten times
earth’s gravity. Designers and manufacturers must account
for this during the entire planning process – representing a
formidable challenge for the engineering teams at the customer
and the tool producer.
16 no. 1, March 2025

materials & tools
Company information
Schumacher has been producing highperformance
cutting tools for more than
100 years. The company’s performance
characteristics are – in addition to first-class
product design – the provision of flexible
services in the areas of customer-oriented
research and development, warehouse
management, logistics and after-sales support.
Schumacher is transforming from a
traditional tool manufacturer to a service
provider integrated into an international
production and university network.
Measuring the cutting edge and the surface quality
Thermal and mechanical challenges
in space
In addition to such mechanical stress, extreme
thermal forces play a role. The near-perfect
vacuum of space results in vast temperature
fluctuations between the sunlit and shaded
sides of a component. Sunlit surfaces can heat
up to approximately 120° C, while shaded
areas cool to around - 90° C. Components
exposed to such cycles, especially in geostationary
orbits, must endure years or decades
of thermal strain. Internal heat sources, such
as electronics used for signal amplification,
compound these issues. Active electronics
create consistent heating and cooling cycles,
adding further complexity.
Such high thermal and mechanical demands
place unique requirements on materials. Highperformance
aluminum and iron-nickel alloys
with low thermal expansion coefficients are
often employed. Two examples serve to highlight
the implications for customized threading
tools:
cracking during thread production, which in turn poses a risk
to the flawless process in the component.
3. chip formation: due to the abrasive nature and high hardness of the
material, chips tend to break irregularly, further complicating process
control. In addition to burrs very short chips are also a challenge for
aerospace components should they remain in the workpiece unnoticed.
For aluminum with such high silicon content (more than 35 %), conventional
thread tool geometries are modified prior to production. Collaborations with
research institutions, such as Research Institute Forschungsgemeinschaft
Werkzeuge und Werkstoffe (FGW) in Germany, have resulted in geometry
changes, like optimized cutting angles and modified relief angles in combination
with a customized surface treatment. Combined, these measures
ensure burr-free chip formation and smooth thread flanks.
#2 – tailored solutions for special nickel alloys
For iron-nickel alloys with high nickel content, threading tools face unique
challenges due to the material’s particular abrasiveness. Cutting angles are
adjusted, and cutting edges are coated with multi-layer friction-resistant
materials to maintain the required thread flank quality.
In both cases, achieving process reliability involves modifying tool geometry
and using coatings tailored to the application. This ensures threads
meet the extreme demands of aerospace systems.
Advanced materials for
space applications: #1 – aluminum
Threads in high-performance aluminum
alloys must be burr-free and particularly
smooth for aerospace applications. The use of
high-alloyed aluminum components is characterized
by three aggravating factors:
1. increased wear: the high silicon content
leads to an abrasive effect on cutting tools,
as silicon is very hard. In addition to
rapid wear, this can cause damage to the
tools’ cutting edges, which represents a risk
factor in view of the need to avoid burrs.
2. brittleness: AlSi alloys with a high silicon
content are often more brittle, which
increases the risk of material chipping or
Special tap lines
for aerospace applications
no. 1, March 2025
17

materials & tools
Preventing burr formation in space
Minimizing burr formation is critical in
space applications, as even small debris
can endanger sensitive onboard electronics
in a microgravity environment. Threading tool
designs are focused on producing burr-free
results to mitigate these risks and ensure
system reliability. In this context, process
security has a disproportionate role in the
entire process:
small failures can lead to severe technical
and economic consequences, with the
complete failure of a satellite system
in orbit as the ultimate negative effect.
entire production process to quality
control and technical support for the end
customer. German specialist company
Zoller from Pleidelsheim was a close partner
for the metro logy section of this.
Testing new materials for space components
Consistent support along the value chain is key
From initial design to final production close collaboration between tool
manufacturers and aerospace manufacturers is essential. This includes optimizing
peripheral systems, such as clamping technologies, coolant-lubricant
systems and pre-drilling tools. Adjusting cutting parameters and defining
tool lifespan are critical to meeting the demands of burr-free results and
process safety.
Process monitoring and measurement technology play a particularly
important role in the production of flawless threads for aerospace components.
In a process lasting two decades we have succeeded in guaranteeing
redundancy-free data transmission from the design stage through the
The core element of metrological monitoring
is the contact-free method of continuously
checking any decisive parameter, both in the
geometry of the tool and in the surface treatment
(roughness of the surface and defined
rounding of the cutting edges). In the specific
case of micro taps for aerospace components,
the surface is monitored using a metrological
process during the production process and
after coating. These methods work optically
without contact using laser light and a measuring
microscope. The measuring spot measures
10 x 10 mm and even the smallest contours
and geometries of less than 1 μm accurately.
In addition the inspection devices handle
complex geometries, such as cutting edges
and thread flanks on cutting segments of taps
with helixes of up to 45 °. Thanks to its large
vertical working or positioning adjustment
range (Z-axis), the unit measures very small
tools flexibly and with repeatable accuracy.
Schumacher’s service engineers supervise
the application process and quality control
with regard to surface finish and burr prevention.
This process is important when setting
up production for the first time, especially in
the case of new regulations from the customer.
Satellite technology is constantly exposed to
new requirements and the components continue
to develop accordingly. This affects both
the workpiece materials and, above all, the
design of the thread. Over the years the company
has found that early involvement in the
design phase is advantageous for the subsequent
process.
Aluminum space component with M1.4 threads
further information: www.schumachertool.de
18 no. 1, March 2025

Precision solutions for metalworking
materials & tools
SIMTEK Präzisionswerkzeuge GmbH will be
presenting its latest innovations at INTEC in Leipzig,
one of the leading trade fairs for manufacturing
and automation technology. Visitors can expect an
extended selection of 3D laser-cut chip form geometries,
the versatile simmill 9W milling tool system and
newly developed, length-adjustable holders in addition
to the tried-and-tested tool range, with a special focus
on individual tool solutions for machining the smallest
diameters.
SIMTEK is setting new standards in chip control with its 3D
lasered chip shape geometries. This technology not only increases
process reliability, but also extends the service life
of the tools. “The introduction of laser geometries marks
an enormous advance in tool technology. It not only makes
our tools sharper and more precise, but also enables them to
reliably meet the requirements for chip control”, explains
CEO Norbert Seifermann.
According to SIMTEK, the 3D lasered tools are ideal for
applications in the automotive industry, medical technology
and other sectors with high demands on precision and process
stability. The number of customers using cutting tools
with 3D laser geometries from SIMTEK has increased more
than tenfold since 2019.
simmill 9W – monoblock performance meets
modular flexibility
Another highlight is the simmill 9W tool family. It combines
the precision and stability of monoblock tools with the
flexibility and cost-effectiveness of modular systems. The
system is particularly suitable for applications such as grooving,
parting and slotting – for example in the automotive
Norbert Seifermann:
“With the simmill
9W series, we are
closing the gap between
classic, modular
interchangeable molds
and monoblock
solutions”
Lasered chip form geometries are the focus at INTEC:
they optimize chip control and chip breaking, especially in
demanding applications such as complex geometries,
varying machining directions and large forming depths
industry, in mechanical engineering and for demanding
precision applications. “With the simmill 9W series, we are
closing the gap between classic, modular interchangeable tools
and monoblock solutions”, explains Norbert Seifermann.
Thanks to innovative toothing technology the system guarantees
maximum stability and precision – even with milling
depths of up to 16.5 mm in the standard range, which is far
beyond the capabilities of many other comparable tool solutions.
With standard cutting widths from 0.5 mm to 6.0 mm
and an integrated coolant supply, the series scores highly in
terms of both efficiency and sustainability. In the individual
area, the application possibilities in terms of diameters,
widths and depths are even greater.
Length-adjustable holders for maximum flexibility
The length-adjustable clamping holders and carrier tools are
specially designed for small series production and individual
requirements. Highlights include the simturn DX clamp
holders with infinitely variable length adjustability and
patent ed ME clamping principle, which offers high stability
even with long overhang lengths.
Thanks to their versatility the length-adjustable holders are
not only particularly economical and flexible to use, but also
help to reduce the variety of tools required by users.
no. 1, March 2025
19

materials & tools
Grooving and longitudinal turning with a simturn TK2 cutting
insert with a chip geometry ground in two directions produces
whirling chips (left); these can wrap around the tool or the
workpiece and lead to downtimes; the lasered version produces
short chips that can be easily removed from the machining
process, thus ensuring high process reliability
Also in the SIMTEK trade fair bag: a new range of lengthadjustable
clamp holders and carrier tools that offer maximum
flexibility for individual production requirements
The simmill 9W family, an innovative milling tool system that
combines the flexibility of modular systems with the precision
and stability of monoblock tools; this version has 12 teeth and
is suitable for cutting depths of up to 16.5 mm – ideal for
demanding industrial applications
The simturn DX clamping holders– a versatile solution for the
internal machining of small components; with their variable
length adjustment and the friction-locked ME clamping system,
they offer maximum stability and precision
The range covers a wide spectrum of applications: from
machining small bores from 0 4.7 mm with simturn AX
carrier tools, to simturn DX carrier tools for bores from
0 7.0 mm, to larger diameters from 10.5 mm with simturn
PX systems. “With these products, we enable our customers
to reduce their tool inventories and still react flexibly to new
production requirements”, emphasizes Norbert Seifermann.
High-precision tools for small diameters and
individual requirements
A growing segment at SIMTEK is the development and production
of tools for machining in the smallest diameters. The
standard range already includes numerous tools from the
simturn AX, simturn DX and simturn PX product families,
which have been specially developed for this purpose. However,
SIMTEK users are not restricted to the use of standard
tools. With more than 10,000 individual tool concepts per
year, SIMTEK offers customized tool solutions for small diameter
applications. Thanks to many years of experience
in the customization sector and the use of laser-cut chip
geometries, users benefit from economically viable custom
tools even for small batch sizes – regardless of whether they
are based on existing standard tools or developed from
scratch.
further information: www.simtek.com
20 no. 1, March 2025

materials & tools
Engineered in record time
MAPAL tool management for DEUTZ in Spain
Already 1875 engines were built at the site in Zafra
where today DEUTZ has its main factory for processing
engine components. Engine blocks, cylinder
blocks, connecting rods and gears are here produced
by around 500 employees in modern manufacturing
facilities for the group’s assembly lines in Cologne and
Ulm as well as for other customers.
DEUTZ’s new 3.9-liter diesel engine is mostly used in agricultural
and construction machines. As an industrial engine
it is designed for long service life and is to be built until at
least 2035. Series production is to start in the coming year
after the current prototype phase. 50,000 units are to be
produced per year. This engine, which will be available in
a power range from 55 to 160 kW, is an important future
project for Deutz. As it is the same size as its 3.6-liter predecessor,
it can be installed in the same vehicles where it will
provide very efficient performance.
“Our engines are typically deployed in off-highway applications
like agricultural and construction machines, which
are in constant use and move heavy loads. We’ll continue to
need internal combustion engine to move those machines.
For the time being, it will be in the form that we use today:
the diesel engine. Synthetic fuels or hydrogen can considerably
prolong their deployment”, explains Alejandro Castilla
De La Hoya, Zafra plant manager. He points out that the
income from this area finances DEUTZ’s investments in
the green segment, which is dedicated to the mobility transformation.
The 3.9-liter diesel engine is already set to run
on gas or hydrogen in the future. “Based on today’s design,
this diesel engine can become a green engine in the long
run”, says Manuel Rodríguez López, industrialization manager.
This is possible thanks to a package of small modifications,
particularly to the cylinder head. Otherwise the engine
remains mostly the same. MAPAL is already collaborating
on DEUTZ’s first hydrogen engine – a whopper at
7.8 liters.
Two weeks from design freeze to offer
“Our clients’ development periods for new parts are becoming
shorter and shorter”, explains Thomas Spang, global head
of tool management at MAPAL. For tool manufacturers
or complete suppliers like MAPAL this represents a growing
challenge. This is, above all, true if plans change at the last
minute, while the deadline for the tool design remains the
same. For the engine block of the new 3.9-liter diesel engine
the company had only two weeks after the design freeze to
complete a final offer.
An ardent team of experts in Aalen were able to complete
this ambitious task on time. Well-tuned workflows proved
The Zafra site in Spain is the main component plant for
the machining of DEUTZ engine parts
advantageous for the team as did the many years of experience
with the client’s production methods. MAPAL has been
conducting tool management for DEUTZ in Spain for 18
years. Several projects have been completed together over the
years.
MAPAL already engineered the machining of the engine
blocks for the predecessor 3.6-liter diesel engine, which
meant they were able to draw on practical experience and
didn’t have to start from scratch. For example from previous
projects the tool experts already knew which machines the
engine manufacturer has. DEUTZ has equipped its assembly
line in Zafra with new five-axis machines over recent years,
so they can switch to new products with relative ease.
When DEUTZ sent their request, the tool management
department and the technology expert team (TET) in Aalen
thought about to the production process. “To be quick here,
we don’t concern ourselves with details at this early stage, but
instead pull together reference tools and concepts from previously
completed projects”, explains Harald Traub from TET.
He is responsible for planning the entire process as project
engineer. “In this way we are able to specify an approximate
budget and the rough scope of the tool package for the client.”
One hundred different tools for an engine block
After this rough planning the concrete tool design followed
in the second week. MAPAL’s offer for the series production
of the motor block included almost 100 different tools in
the end. Many of them are custom tools that achieve short
machining time and thus high economic efficiency. Aside
from these standard tools are used for milling above all.
To produce prototypes quickly a few close-to-standard
tools were also used. Series production could then begin
with the optimal set of tools. As part of their original
no. 1, March 2025
21

materials & tools
Compared to its predecessor
the HPR400 reamer for
fine machining crankshaft
bearing journals has three
times the tool life and does
not require resetting;
Sergio Aranda
(MAPAL tool setter)
sees a clear difference
Inspection of the machining quality on a prototype of the engine
block for DEUTZ’s 3.9-liter engine (left to right):
Jorge Montaño (Process Technician),
Juan Jesus Roldan (MAPAL engine block technician),
David Castaño (MAPAL tool manager) and
Armando Gutierrez (quality engineer)
delivery MAPAL supplied consumable tools as well as the
required tool holders and adapters to DEUTZ. All other
consumables were handled by the tool management on site.
From that point on the client no longer payed per tool but per
completed part – i.e., the cost per part is billed.
The unit costs at first correspond to the price determined
during engineering. Certain ratios have been agreed upon
for the following years. The client receives an increasing percentage
of rebate and therefore pays a bit less per unit every
year. For this business model to work out, MAPAL has to implement
continual improvements to save costs. This is done
with new tool technologies and corresponding optimization.
The costs per part are fixed over the term of the contract, after
which a reassessment takes place. Such contracts, which run
over four to five years, offer the client planning security.
“With our engineering expertise we support DEUTZ
beyond the tool-setting area and cultivate a close partnership”,
Spang highlights. After helping to build the prototype it is
the tool management’s turn to shine on-site during series
production. DEUTZ uses approximately 1,300 different tools
in total. Thousands of tools are available from stock and have
to be managed in Zafra. To keep inventory at an optimal level
(i.e., avoiding bottlenecks while preventing unnecessarily
high tool stocks), MAPAL uses its own warehouse management
systems and digital solutions with the cloud-based software
c-Com for tool management. The digital Tool Management
4.0 doesn’t only handle procurement processes, which
are initiated semi-automatically, it also acts as a reporting
tool to analyze cost drivers and stocks.
Tools just in time for the assembly line
Industrialization manager Manuel Rodríguez López praises
the good collaboration with MAPAL when it comes to tool
management: “Over the course of our cooperation we have developed
extensive technological concepts, which go far beyond
mere logistics. Besides achieving cost reductions, tool setting
is particularly important for us. The MAPAL employees
working on-site have a lot of know-how and ensure that production
has exactly the tool they need at the right time.”
MAPAL’s tool manager on site is David Castaño, and also
employs tool setters permanently in Zafra. They make sure
that a dozen different parts are produced without a hitch. “It
is very beneficial to have David here on-site with us”, emphasizes
Manuel Padilla Fernández, manufacturing engineering
manager at DEUTZ, who works closely with the tool manager.
“We can talk about any opportunities for optimization
directly at the machine. We don’t consider David Castaño to
be an external service provider but rather a part of our team.
It’s a very strong cooperation.”
During a team meeting, the MAPAL tool manager explains
machining with the HPR400 reamer and the differences
compared to the previous system: (left to right)
David Castaño (MAPAL tool manager), Manuel Padilla Fernández
(DEUTZ manufacturing engineering manager) and
Rafael Salinas (DEUTZ project manager)
Developing together to solve problems
If required, new tool solutions can be developed in Aalen via
the local MAPAL team. That was the case when it became
necessary to optimize the tools for machining the bore in the
crankshaft and camshaft. In cooperation with DEUTZ, a new
machining concept from MAPAL with the HPR400 reamer
was implemented. David Castaño is convinced of its advantages:
“The tool life of the previous tool was 350 units and
resetting was required every 100 units. With the HPR400, we
achieve a tool life of 1,000 parts without resetting. The resulting
machining quality is exception ally good.”
further information: www.mapal.com
22 no. 1, March 2025

news & facts
Seamless transition
HORN USA expands production with its own HiPIMS coating systems
In 70 countries the top players in automotive, chemical,
aerospace, medical technology and tool and mold
making industries trust HORN’s precision tools to
drive their success. The USA is one of the most significant
markets for the cutting tool industry and is becoming
increasingly so. In its quest for perfection and
enhanced service, HORN USA has now integrated a
state-of-the-art coating line with two CC800® HiPIMS
systems into its production process.
This allows HORN to supply US customers rapidly with customized
solutions for their individual requirements. The
trust built over years of collaboration between HORN and
CemeCon in Europe and North America has paved the way
for a seamless transition to in-house coating for HORN USA.
HORN’s trademark is delivering high-quality precision tools
for demanding machining operations with short delivery
times, which is where others struggle. To guarantee this
worldwide, high-performance production facilities is needed,
with cutting-edge technology around the globe – especially in
key markets such as the USA. At the main plant in Tübingen,
Germany, the unique HiPIMS technology from CemeCon has
long been one of the cornerstones of HORN’s success. Since
2004 HORN USA has had its precision tools coated by the
experts at CemeCon, Inc. Now the production in Franklin,
TN has been expanded and enhanced with in-house coating
expertise to be able to support the US market quickly and
efficiently with fully optimized products.
The perfect combination for in-house coating
“It was clear to us that if we were to switch to our own coating
production, we had to produce the same coatings ourselves,
from day one. We needed to produce the same quality as
before using CemeCon’s coating service and we needed the
new products from Tübingen to be easily duplicated in the
US. In other words, we needed the same technological capabilities
as in Germany. And the training to not only integrate
the coating technology into US production, but also to fully
take advantage of its potential”, says Chad King, general
manager at HORN USA.
HORN looked for and found a solution with its longstanding
partner CemeCon. HORN invested in a turnkey
coating line – consisting of two HiPIMS coating systems, substrate
pre- and post-treatment equipment and all other necessary
peripheral systems – with technology “made in Germany”
and training “made in the USA”. Chad King comments:
“With CemeCon as our technology partner, we have received
the all-inclusive turnkey package: first, the technical equipment
and second, the full customer service package complete
with knowledge transfer, training for our employees and
support from the coating experts from Horseheads, NY, in
collaboration with our German colleagues. This combination
is perfect and allows us to do an outstanding job!”
Unique knowledge
transfer ensures a
smooth start
When integrating
an in-house coating
line into the production,
CemeCon has a
decisive advan tage:
the experts use the
same technology in
their coating service
every day – in all coat -
ing centers around
the globe. As a result
the team at CemeCon,
Inc. knows the coating
and peripheral
The CemeCon coating line with
two CC800® HiPIMS was seamlessly
integrated into the production process
at HORN USA
systems, processes
and workflows down
to the smallest detail
and provides its customers
with optimum
support. “HORN and CemeCon have a decadeslong
partnership – both here in the USA and in Germany.
This means we know HORN’s requirements and high-end
quality level inside out”,” says Ryan Lake, sales manager at
CemeCon, Inc.
The operation of the HiPIMS coating system is self-explanatory;
the key to the success of in-house coating production
lies in understanding the workflows and the entire process
from start to finish. Over the years CemeCon has optimized
the processes so that they are easy to learn and understand.
“We pass on our knowledge and experience during training
at our coating center in Horseheads, NY, or at the customer’s
site. The training is identical for customers and our own
employees. We know from our own experience that our
training quickly and reliably imparts the know-how needed
to master the coating process successfully. And if there are
still questions, we continuously support our customers whenever
it is needed”, says Eli Roberts, technical manager at
CemeCon, Inc.
Seamless continuation of quality
Chad King: “For just over a year we’ve been revolutionizing
our coating production in Franklin, thanks to our dynamic
partnership with CemeCon. By blending cutting-edge technology
with unparalleled process expertise and synchronized
training, we’ve achieved a flawless transition to in-house
coating. From day one we’ve delivered exceptional quality
and gained the power to innovate our coatings and tailor
them to our exact needs.”
further information: www.cemecon.com
no. 1, March 2025
23

news & facts
Machine tool digitalization software portfolio,
in the U.S.
To meet the increasing productivity, quality and efficiency demands of the machine tool market,
it’s very important that manufacturers optimize their machining tasks – that’s where MACHINUM comes in
Siemens, a global leader in technology for industrial
automation hardware, digitalization software and services,
announced its U.S. launch of MACHINUM.
MACHINUM is the CNC digitalization software portfolio
designed to manage, analyze and optimize shopfloor performance
and aims to help machine tool users and builders improve
their operations and productivity through seamless
software integration.
The digitalization portfolio is integrated into Siemens
Xcelerator, allowing companies in the machine tool sector
to better facilitate digital transformation – making it more
efficient, faster and scalable in both manufacturing and
design, and the demand for energy efficiency, sustainability
and high-quality product manufacturing. The technology is
not only for SINUMERIK-controlled CNC machines, which
allows the portfolio to be integrated into any existing manufacturing
environment to future-proof the shopfloor.
“It’s important for manufacturers to start or enhance their
digitalization journey, and MACHINUM can help optimize
industrial automation operations at any scale”, said Dave
Morley, mid-market sales manager, Siemens Digital Industries.
“Siemens developed a digitalization portfolio that
drives increased usability and capability, and at a lower cost,
to provide greater access to this technology. Companies
that can produce quality parts faster and more efficiently
will continue to outcompete competition – and integrating
MACHINUM can help do just that.”
The portfolio is made up of three pillars: Smart Machine,
Smart Shopfloor and Smart Virtual Machine. Smart Machine
offers lower programming and material costs, higher quality
machine uptime and overall faster machining by using
machine data for real-time, in-process quality control. Smart
Shopfloor provides customers with lower material, operational
and programming costs, along with higher utilization,
through more efficient preparation and pre-production
resource management. Smart Virtual Machine offers lower
programming costs and higher quality and utilization for
better machine engineering with the integration of digital
twin and closed-loop engineering.
Each pillar enhances performance, allowing users to increase
speed, agility and endurance of their operations. Within
the Smart Virtual Machine pillar companies can use digital
twin to enable dependable virtual machining processes,
accelerating the run-in of new parts and reducing costly
downtime.
The MACHINUM portfolio features Adaptive Control
and Monitoring (ACM) which allows users to reduce their
machining times by up to 15 % and extend the life of their
cutting tools, leading to greater manufacturing productivity.
further information: www.siemens.com
24 no. 1, March 2025

news & facts
CERATIZIT achieves Gold rating from EcoVadis
CERATIZIT is proud to announce that it has been
awarded a Gold rating from EcoVadis, placing the
company among the top 3 % of companies in its industry
for sustainability performance.
“The gold rating is a testament to the dedication and hard
work of many colleagues across various departments at
CERATIZIT”, said Andreas Lackner, spokesman of the executive
board at the company. Over the past two years the company
has made significant progress, moving from bronze to
silver, and now achieving gold, meaning that CERATIZIT are
among the top 5 % of all companies assessed. In its industry
they were ranked even higher, being one of the top 3 %.
EcoVadis rating highlights company’s strong ESG
performance and commitment to sustainability
EcoVadis is a globally recognised platform that provides sustainability
ratings, information and tools to help companies
manage environmental, social and governance (ESG) risks
and compliance. It rates companies on four themes: environment,
labour & human rights, ethics and sustainable procurement.
“Our latest EcoVadis rating shows that we are on
the right track”, added Lackner. “Apart from providing our
customers with excellent performance, quality and service,
we also want to support them in creating solutions for a more
sustainable future.”
CERATIZIT has been awarded a Gold rating from EcoVadis
As part of its global sustainability strategy the company has
set an ambitious goal to become the sustainability leader for
the carbide and cutting tool industry by 2025. This recognition
from EcoVadis is a significant milestone on that journey.
“We are thrilled to be recognized as one of the industry
leaders in sustainability”, says Lackner. “This gold rating
from EcoVadis motivates us to continue our efforts and drive
positive change in our industry.”
further information: www.ceratizit.com
Platinum Tooling offers custom and special tooling
engineered by Heimatec
Platinum Tooling, the exclusive importer of Heimatec
live tooling for the North American machine tool accessory
market, offers custom designed and special
tooling for most major CNC turning centers, in addition
to their extensive standard tooling line.
Heimatec will design and build custom tools to suit specific
requirements for most CNC lathes, regardless of application,
brand or size, with the same superior quality as their standard
tools.
Platinum Tooling Technologies, Inc. is known as a tooling
industry source for problem solving and tooling application
expertise. Now, tooling experts at the company will work
directly with customers to design custom tools that solve
specific application and manu facturing needs.
Heimatec, a world leader in live tools, angle heads and
multi-spindle drill heads, manufactures tools for the most
popular machines, such as: DMG Mori, Doosan, Eurotech,
Haas, Hardinge, Hurco, Hwacheon, Hyundai, Mazak, Miyano,
Murata, Nakamura, Okuma, Samsung, Spinner, Takisawa,
Victor Fortune and Yama Seiki.
Platinum Tooling’s headquar
ters is in Illinois,
Prospect Heights, where
they in ventory a wide
range of live and static
tools for most standard
applications. The world
headquarters for Heimatec
is in the Black Forest area
of Renchen, Germany.
As Platinum Tooling
president Preben Hansen
explains “A growing portion of our business is centered on
custom tools for specific applications. Customers bring us
their toughest challenges, whether those involve exotic materials,
depth of cut, extensions needed, rotary table and fixture
positioning or other machine tool arrangements. Our engineers
work to provide the optimum solution in cutting time,
mechanical motion and productivity performance.”
further information: www.platinumtooling.com
no. 1, March 2025
25

news & facts
Going west:
Innviertel know-how in high demand in the US
Fill Machine Engineering is continuing its internationalization
efforts and stepping up its sales activities on
the North American market.
Fill USA, Inc., a wholly owned subsidiary of Fill
Machine Engineering headquartered in Plymouth,
Michigan, is embarking on a sales offensive in its third
year of existence.
In recent months the Fill USA, Inc. team, together with colleagues
from Gurten (Austria), showcased its high-tech
machine engineering solutions at prestigious trade fairs and
events across the country. Marc Perberschlager, general manager
of Fill USA, Inc., has been supported in this endeavor
by US sales professional Nolan Strall since September 2024.
Mr. Strall has many years of experience in machine engineering
and automation, primarily for the composites and aerospace
industries, and boasts first-class contacts in these fields.
From 2025 two more Fill service technicians will be relocating
to the US site, with more to follow in the near future.
“We see great potential for our innovative technologies in
North America. By stepping up our activities we wish to acquire
new customers and further expand our market position”,
explains Fill CFO Martin Reiter, responsible for the US
subsidiary in his function as president. Besides distributing
SYNCROMILL machining centers the com pany’s activities
focus in particular on production plants and non- destructive
testing systems for the aerospace industry. It also serves as
a hub for projects from other Fill competence centers. General
manager Marc Perberschlager is the first contact for
customers and partners on site, acting as an important
link to sales and technology at Fill’s headquarters in Austria.
Making a mark with expertise and know-how
Fill has built an excellent reputation worldwide as an ideas
factory for customized complete solutions in the area of special
machine engineering. With an export quota of approximately
90 % the company is highly successful on the international
market. In the past few months the Austrian machine
engineering specialist showcased its expertise and knowhow
at numerous trade fairs throughout the US, including
the IWF International Woodworking Fair in Atlanta, the
CAMX – Composite and Advanced Materials Expo, San Diego,
the ATLAS Composites and Innovation Summit (ACIS),
Wichita, the NADCA Die Casting Congress & Tabletop
Indianapolis, and the ASNT Nondestructive Testing Conference
in Las Vegas.
Major projects underway
Fill is currently in the process of implementing two major
projects for US customers – a processing line for graphite
electrodes and a system for handling aluminum plates. The
on-site installation and commissioning of these large-scale
systems will take several months and should be completed by
mid-2025.
further information: www.fill.co.at
Acquisition completed
Sandvik has completed the previously announced
acquisition of pro-micron GmbH, a German-based
supplier of sensorised tools and automation software.
The company will be reported in Sandvik Coromant, a division
within Sandvik Manufacturing and Machining Solutions.
Pro-micron, founded in 2002 has around 56 employees and
is headquartered in Kaufbeuren, Bavaria, Germany. In 2022
the company generated revenues of about SEK 88 mil. The
impact on Sandvik’s EBITA margin and earnings per share
will be limited.
further information: www.pro-micron.de
26 no. 1, March 2025

Simple calculation of the CO 2
footprint
of a machine tool
news & facts
What is the CO 2 footprint of a machine tool? The
answer is not easy: After all, a machine tool consists of
tens of thousands of individual parts, including purchased
materials and preliminary products. There
is a huge variety of products, ranging from compact
milling machines for intricate clock mechanisms to
presses for aircraft parts: almost every machine is
unique. How do you arrive at a value that is also valid
and comparable for accountants?
“The CO 2 assessment itself is already complex”, says prof.
Felix Hackelöer from the Institute for Automation and
Industrial IT at Cologne university of applied sciences, “and
it is very complex for machine tools.” Hackelöer is a member
of a group of experts formed on the initiative of the VDW
(German Machine Tool Builders’ Association). The group was
faced with the task of developing so called product category
rules (PCR) for machine tools, involving calculation approaches
that can be used to determine the product carbon
foot print (PCF), i.e. the CO 2 of a machine tool. Also on the
team: experts from six VDW member companies – Chiron,
DMG Mori, Grob, Heller, Schuler and United Grinding – as
well as experts from the VDW and VDMA departments
involved in standardization. The VDMA aims to create a
guideline that can ideally be developed into an ISO standard.
Premise: ensure applicability also for SMEs
The group met first in February 2024. There was a short discovery
phase in which different experiences were reported
and possible approaches were discussed. Jörg Süssdorf, global
quality manager at Schuler Pressen, Göppingen, reports
that agreement was quickly reached on a few key points:
“Many companies long for a simple, well-structured paper;
we agreed that our rules must also be able to be implemented
for SMEs without a great deal of bureaucracy.” The results being
comparable and internationally adaptable. However, they
should also make it possible to recalculate or check if market
participants appear to be less trustworthy. Finally, the goal
was set that the PCF could be calculated in a single day using
the method to be developed. Until then, three months at best
was considered realistic.
The method: just don’t get too lost in the details
The PCF includes all greenhouse gas emissions caused by a
product in the various phases of its life cycle. The VDW project
group agreed on the cradle-to-gate approach, i.e. an approach
that focuses on resources, the manufacture of preliminary
products and finally the production of the end product, right
up to the point at which the machine leaves the manufacturer’s
factory. The “most heated” discussions in the expert group
were about how many detais were needed. “Higher-level
approaches require a detailed consideration of up to 99 % of
a machine’s mass” says Felix Hackelöer. “This is not possible
with machine tools.” According to the Cologne scientist the
question was as to what sense it makes to calculate the PCF
down to the smallest washer. The aim of the working group
being to develop a methodology for the PCF of machine tools
that combines good accuracy with reasonable effort.
New VDMA standard:
a streamlined complete package
The now available PCRs from the VDW project group guide
users in nine steps through the process. This is primarily
about the machine and its individual parts. The emissions
generated directly on site by the machine manufacturer
are taken into account, as well as purchased energy sources,
which are allocated to the machines produced accordingly.
The manufacturer must first define the coverage limits. Is it
just about a company’s own product or the entire scope of delivery,
including the loading robots, for example? The machine
is then virtually dismantled. All individual parts are
sorted by weight using the parts list. Control cabinets and
motors must be considered separately, as they may contain
CRM (Critical Raw Materials) such as rare earths, copper
or cobalt, which are associated with high emissions. The
guideline provides a practical approach for their accounting.
Then the remaining mass of the machine (after deducting the
control cabinet and motors) is considered. Here the experts
decided to apply the Pareto principle (80/20 rule), named
after the Italian economist Vilfredo Pareto, to simplify
matters. Applied to the machine tool it means that a few parts
make up the majority of the mass – and therefore also the
carbon footprint. The task now is to use the sorted parts list
to identify the parts that make up at least 80 % of the remaining
mass. Their PCF can then be calculated by multiplying
the weight by the appropriate emission factor. The emission
factors of the various materials can be obtained either from
the supplier or from relevant databases. The remaining parts
that have not yet been reported can be extrapolated accordingly,
which is quick and, according to the experience of the
experts, leads to a comparable level of accuracy as a complete
consideration of all parts, as Hackelöer emphasizes. The addition
of the individual footprints results in the product carbon
footprint of the entire machine tool, which is specified as an
equivalent in kg – a value that can be included in any sustainability
report, checked and compared with others.
Recommendation at the right time
For Dr. Matthias Baur, team coordinator for structural and
process dynamics at Grob-Werke, Mindelheim, the work on
the VDMA standard came at just the right time. The EU CSRD
(Corporate Sustainability Reporting Directive) will require
the majority of companies to produce comprehensive sustainability
reports from 2025. Two years ago, a visitor survey at
EMO Hanover revealed that the focus on the future of sustainability
in production was high up on the priority list for
68 % of visitors, and even more so for foreign visitors (three
quarters) than for German visitors.
further information: www.vdw.de
no. 1, March 2025
27

news & facts
fairs
JIMTOF 2024
Experiencing of what the future of metalworking is holding
The crowd at Tokyo Big Sight, the modern Tokyo
International Exhibition Center on Tokyo bay, was
huge from the first day on, demonstrating the importance
of JIMTOF, the JAPAN INTERNATIONAL
MACHINE TOOL FAIR among the international
metalworking exhibitions.
On November 5, 2024, JIMTOF 2024 opened at 8:30 a.m.
local time at Tokyo Big Sight for six days. The theme of the
exhibition was “Technologies passed down to the future
offers unlimited possibilities”.
The 32nd edition of JIMTOF was the largest ever in both
terms, the number of exhibitors and booths. 175 companies
and groups more than the last JIMTOF in 2022, 1,262 companies
were exhibiting in 5,743 booths, making it the largest
JIMTOF trade show to date. Compared to the previous
show there has been a significant increase in the number of
overseas companies exhibiting, with 230 companies from 19
countries and regions including China, Taiwan, Germany,
Sweden, the United States and India.
The crowds were huge as soon as the fair opened. On the
first day over 18,792 visitors (including 3,205 from overseas)
flocked to the exhibition center at the harbour. Shortly after
the opening ceremony, halls 1 and 2, where the machine tools
and precision machines were exhibited, were already well attended.
And the other halls soon filled up as well.
On the first two days alone 41,000 visitors filled the exhibition
center, an increase of 16 % compared to 2022, announced
Kazuharu Iwase, CEO of the exhibition company Tokyo Big
Sight Inc. at the JIMTOF press conference.
JIMTOF 2024 introduced the latest products and technologies
of participating companies from a wide range of products,
including metal cutting machine tools, metal forming
machine tools, machine tool accessories, tools for machines
(cutting tools & wear-resistant tools), diamond and CBN
tools, grinding wheels and abrasives, gears and gear devices,
oil hydraulic, pneumatic and water hydraulic machinery, precision
measuring machines and instruments, optical measuring
instruments, testing machinery and control equipment
and related software (CAD, CAM, etc.).
Yoshiharu Inaba, chairman of the JMTBA, emphasized the
four main themes of the trade fair which are:
JIMTOF 2024, the 32nd edition of the exhibition, is opened
Welcoming the international press (left to right):
Kazuharu Iwase, executive vice president and CEO
Tokyo Big Sight;
Kazuo Yuhara, president Japan Machine Tool Builder’s
Association;
Dr. Yoshiharu Inaba, chairman of Japan Machine Tool
Builder’s Association and chairman FANUC Cooperation;
Katsutoshi Matsuura, president of Matsuura Machinery
Cooperation and director of Japan Machine Tool Builder’s
Association;
Tsuneyuki Ishii, chairman of International Commitee,
JMTBA and president of Okamoto Machine Tool Works
1. Service enhanced competence solutions, not just
about machines.
2. Decarbonisation and approaches on expanding the use of
digital technologies and decarbonizing and saving energy.
In recent years, with the improvement of simulation
technology, there have been case studies of technologies
that digitally reproduce machine characteristics to predict
the machined surface of a workpiece, automatically
calculating machining time and manufacturing costs by
utilizing 3D models on a simulation, and estimating the
power consumption and CO 2 emissions.
In addition the use of sensors for advanced monitoring of
machine conditions, idling of peripheral equipment and
optimum control of coolant flow, among other efforts to
curb CO 2 emissions, are also in progress.
3. Automation, i.e. the use of robots to support automation
and labor savings. The entire manufacturing industry is
facing an urgent issue of how to respond to the shortage
of labor due to the decline in the working population. At
the most recent EMO and IMTS exhibitions there were
many initiatives to support automation and manpower
saving by utilizing cooperative robots and AGVs,
and this trend continues at JIMTOF.
The use of robots is expected to further expand, not only
in loading and unloading of workpieces but also in some
processes of machining, cleaning and measurement,
as well as in cases where robots contribute to stable
production by operating in combination with automatic
program correction devices that use image sensors.
28 no. 1, March 2025

fairs
news & facts
Shortly after the exhibition opened, the modern and architecturally impressive Tokyo Big Sight International Exhibition Center
filled to capacity; visitors were treated to a glimpse of tomorrow’s technologies
4. Additive manufacturing, expanding production possibilities.
The advancement of AM technology is expanding the
range of products from prototypes to actual products and
from conventional manufacturing processes to processes
that achieve higher functionality and lighter weight through
AM especially for molds and medical parts.
Recently exhibits have included not only stand-alone AM
machines but also system solutions with both front-end and
back-end processes, like simpler support removal after molding
or examples of applications to large components.
Following on from JIMTOF 2022, JIMTOF 2024 had set
up the special exhibition “Additive Manufacturing Area” in
the south exhibition hall area, where innovative products and
technologies related to Additive Manufacturing (AM) and
3D printer-related products and technologies could be seen,
attracting attention as innovative technologies in the manufacturing
industry. A special seminar venue was set up in
the area where 53 exhibitors introduced their latest products,
cutting-edge technologies and every day solutions.
Visitors walking through the exhibition halls had the opportunity
to get a complete overview of the future of metalworking,
as manufacturers from all over the world exibited at
this trade fair.
Let’s take a look at the
economic conditions in Japan
Real GDP growth rate (April to June 2024) was up 0.7 % over
the previous quarter (annualized rate: + 2.9 %). Growth was
driven by automobile industry, which resumed shipments
after a temporary suspension, and increased private consumption
of air conditioners, smartphones and the like.
Investments was at + 0.8 % in the same period. With corporate
profits at a high level, investments to address labour
shortages and digitalization were strong.
Machine tool orders and outlook
Cumulative orders from January to September 2024 exceeded
1.11 trillion yen (7.186.186.986 US $) for the fourth consecutive
year. This was the second consecutive year-on-year decline.
Foreign demand accounted for 69.7 %. This was the second con -
secutive year of increase (January to September 2021: 67.6 %).
The quarterly trend showed an increase from the first to the
second quarter, then a decline to the level of the first quarter
in the third quarter. In autumn the situation weakened.
Domestic demand
The total for January to September was below 350 billion
yen for the first time in four years. The year-on-year rate
decreased for the second consecutive year. Among the major
industries, only aerospace, shipbuilding and transportation
machinery recorded increases. Molds, counting as “general
machinery”, saw a drastic decrease of - 44.9 %.
The two sectors with the highest-demand, semiconductor
production equipment and automotive-related equipment,
re covered slower than initially expected.
Foreign demand
The total for the January to September period was below 800
billion yen for the second consecutive year (above 750 billion
yen for the third consecutive year). The year-on-year rate
increased slightly for the first time in two years.
Among the three major markets only Asia saw a year-overyear
rate increase. This was due to the increase in China from
early spring to summer and the healthy Indian market.
The rate in North America has fallen for two consecutive
years due to various factors, such as the high interest rate, the
US presidential election and a drop in orders in the aerospace
industry, etc.
Demand in Europe, particularly in Germany, has been
weak since the summer, caused by high energy prices, low exports
and consumption, weak sales of electric vehicles (EV)
and other factors.
Order outlook
The annual order forecast for 2024 was 1.5 trillion yen. The
progression rate as of September was 73.3 %. The forecast will
not be revised. There are some uncertainties for Europe for
the first half of this year, so it is difficult to forecast a recovery.
However, a better outlook is expected for the other markets.
Kazuao Yuhara, president of JMTBA, pointed out that
automotive production is declining, which is also having
an impact on Japanese mechanical engineering companies.
Orders from the USA and Germany in particular have
declined.
This reflects the impact of sluggish sales of EV, a trend that
is now also being felt in the USA and Japan. But for hybrid
vehicles there is still demand at the moment.
The trade fair, with its always well-attended exhibition halls,
showed little of this reticence on the part of the markets. On
no. 1, March 2025
29

news & facts
fairs
the contrary, a large number of innovations offered a glimpse of future production
processes. This includes, above all, the influence of AI on industry.
These days it is still used mainly for machine-human interfaces making work
easier in order to counter the shortage of skilled labour. A worldwide trend.
AI is still more focussed on machine functionality.
Strolling the aisles
As we walked around the show, we saw many applications of AI.
Manufacturers, including those producing machine tools and machine
parts, are seen actively using digital measures such as digital twins that
replicate the physical world in virtual spaces, and artificial intelligence
(AI). High-precision computer simulations are helping to shorten development
times. Previously, simulations required the creation of prototypes, but
with digital technologies the need for prototyping has been reduced, lowering
both cost and effort. As labor shortages become a serious social issue,
the digitalization of the development and manufacturing process is set to
accelerate.
Okuma has equipped its proprietary computer numerical control (CNC)
system “OSP-P500” with a digital twin feature that will be able to estimate
the processing time at 1/1000 of the actual machining time, with high speed
and precision within a 1 % margin of error.
The digital space within the system contains the latest actual system data
and 3D model data to recreate the system. This enables accurate estimation
of machining time, which contributes to the planing of machining schedules,
fast and accurate delivery dates, and estimation.
This functionality is made possible by Okuma’s fundamental philosophy
of mechatronic integration. Commercial software can perform similar
simulations, but while they can easily replicate the motion of motor-driven
spindles, they can rarely reproduce the operation of other parts such as hy -
draulic peripherals. Electrical engineers may be able to estimate how electrically
operated parts move, but estimating hydraulic units requires further
mechanical expertise. Okuma was able to perfect the mechanism that can
predict every movement of machine tools because of its extensive engineering
expertise in both electricity and machinery.
The new small, horizontal machining center MS-320H, wich made its
debut at JIMTOF, adopts an innovative machine structure. By placing the
table vertically the chips fall down and do not pile up on the table and jigs.
An additional feature, “AI machine diagnosis”, can be added as special feature,
using AI to interpret the machine’s condition and prevent unpredictable
productivity losses. The AI interprets whether there is an abnormality
or nearing end-of-life in the main or feed spindle. If maintenance is required,
it alerts the user, promoting scheduled maintenance and preventing productivity
losses due to unexpected machine downtime.
Mitsubishi Electric premiered a NC
processing AI diagnosis tool for machining
abnormality diagnosis, using AI and machine
learning. The tool is easy to operate with automatic
setting of diagnostic conditions.
FANUC’s Servo Guide 2, which supports
FANUC’s numerical control (CNC) system,
the “series 500i-A” comes standard with Ai
servo tuning, which enables advanced servo
adjustments tailored to each machine, allowing
anyone to achieve stable, high-quality tun -
ing results through AI-based optimization.
Servo Guide 2 features:
1- automatic adjustment of basic performance
characteristics
2- gain and filter adjustment to the main
spindle to improve the performance of
gear machining and other applications
3- support for inch-based G-code programs.
Once the simple initial setup is completed, it
runs automatically.
NAGASE INTEGREX, a manufacturer of ultra-precision grinding machines,
demonstrated AI-based ultra-precision machining that does not rely
on experienced operators. It introduced an AI that recommends optimal
combinations for machines, cutting tools, machining steps and conditions
tailored to the materials. The latest models of ultra-precision grinding
machines are equipped with AI, which enables quality prediction based on
various data collected during the machining process.
Ultra-precision machining involves many factors that affect the results –
such as peripherals, jigs, machining accessories, metrology and environment
– making it challenging to achieve the ideal combination. Adjusting
machining requirements based on factors such as vibration, sound, color,
and odor has traditionally required extensive experience and knowledge.
In March 2024, NAGASE INTEGREX developed, together with three grind -
ing machine manufacturers and the Hokkaido University, a basic technology
in this field. Since then the company has continued its development and
demonstrated its latest technology at JIMTOF.
30 no. 1, March 2025

fairs
news & facts
Machining tools have supported Japan’s key industries,
as cutting-edge technologies always bring the challenge of
machining difficult-to-cut materials. Taking the example of
robotics development, micron-level machining is essential
for smooth robot movements. As a tool manufacturer supporting
all kinds of material processing, Asahi Diamond is committed
to enabling high-precision and high-quality manu -
facturing with diamond wheels/CBN wheels, stationary
dressers and wear-resistant tools.
NIDEC MACHINE TOOL has developed a software
that uses digital twins to perform high-precision simulations
of evaluation processes before the machining of machine
tools. The software can create optimized machining programs
in a virtual space. Without actually setting up machines
and workpieces, the software can simply be used on NIDEC’s
machine tools to enable targeted machining quality and
increase productivity twice or more.
The software is for NIDEC’s double-column 5-axis milling
machine “MVR-Hx”, which will be launched this spring and
could be seen at the fair. It is intended for large workpieces
such as automotive molds.
The HX500 5-axis horizontal machining center made
its debut at JIMTOF 2024. Although it is a 5-axis machining
center it has the same floor space and height as a 4-axis
machining center. Another debut at the show was the ZFA260
gear grinding machine, a world standard gear grinding
machine with high efficiency. New mechanism, double table
structure and high-speed rotation achieve a world-class
non-machining time of 4 s.
And with LAMDA200 NIDEC is innovating the manufacturing
processes and realizing high added value. It is a direct
energy deposition additive manufacturing system. Its DED
(powder position) method enables the production of large
parts. Stable printing is achieved through the unique local
shielding technology and monitoring feedback.
Asahi Diamond supports the technological revolution
of AI at the foundation level by enabling the processing
of semiconductors and other precision devices. Diamond
wheels, diamond cutters, dicing blades and CMP condi -
tioners are among the tools for electronic components and
semiconductors.
One of the hot topics: decarbonization
JIMTOF 2024 featured a wide range of technologies, products
and services that are “energy-saving”, “resource-saving”
and “EV compatible”. Developed by the Japan Machine Tool
Builders’ Association (JMTBA), the “Carbon Neutral Action
Plan” for the machine tool industry outlines the goal of
reducing 225,100 tons of carbon emissions by 2030, which is
38 % less than in 2013. In 2022 machine tool production by
price increased significantly to 1.5594 trillion yen year-onyear,
but CO 2 emissions were reduced only by 310,900 tons,
up 7.8 % year on year.
The association has also established Life Cycle Assessment
(LCA) guidelines for machine tools. The guidelines show how
to measure and understand CO 2 emissions at each step of the
lifecycle, from material sourcing to production, consumption,
and disposal, making it easy to understand the environmental
impact.
Long before carbon neutrality became a global trend, the
machine tool industry was already improving the operational
efficiency of machine tools through measures such as reducing
idle time and optimizing machining requirements, as
well as shifting to high-efficiency units that utilize high-performance
motors, inverter control and so on. Additionally
the industry has played a significant role in energy conservation
for the industrial sector by developing compound
processors that integrate multiple processes into one system
and save power consumption by eliminating hydraulic pressure.
JIMTOF 2024 also fully highlighted technologies and
products that show how these efforts have been further
developed.
Responses to the expected growth of the EV sector are also
underway. Although the EV-related markets have recently
slowed down somewhat, the share of EV’s in the overall automobile
market is expected to increase and grow.
To respond to this situation, machine tool manufacturers
are focusing on proposals for machining parts suitable for
EVs. They displayed many products that highlight their
strengths in technology and know-how, such as machining
no. 1, March 2025
31

news & facts
fairs
technologies that incorporate the use of aluminum and
carbon fiber reinforced plastics (CFRP) to make car parts
lighter, as well as high-precision gear machining designed
for quiet operation.
There are also increasing efforts to use new materials in
machine tools themselves. One of these is mineral casting,
a complex material of ores bonded with epoxy resin as an
alternative to casting. It emits much less CO 2 in the manufacturing
process than casting and has a shorter lead time.
Switching from casting to mineral casting is expected to
reduce CO 2 emissions and shorten lead times in machine tool
production. Some manufacturers showed machining centers
that use mineral casting in machine tool columns and beds.
In order to catch up with these recent trends,
Citizen Machinery offers total solutions based on its
Cincom and Miyano brands, which have their own technologies
such as LFV (Low-frequency Vibration Cutting), FA
friendly which proposes automation and “alkapplysolution”,
Citizen Machinery’s ICT technology to solve not only the
problems customers face today, but also future ones. The L32
CNC automatic lathe is the latest version of one of Cincom’s
most popular products. New types of tooling have been added
for even greater machining flexibility. It is available with various
options such as LFV simultaneous 4-axis operation, CI
tooling system and automatic internal measurement. Demonstrations
of machining complex workpieces using B-axis
tooling with an automatic tool changer (ATC) and internal
measurement were shown. The Miyano ABX65/80THY, a
fixed-headstock CNC automatic lathe made its debut at the
fair. The new ABX series is equipped with a 0 80-/0 65 mm
front spindle. The rear spindle has 0 65 mm. Combined with
three turrets equipped with a Y-axis, this expands the range
of workpiece machining capabilities. The product design has
also been completely revised. A large window and a 19-inch
touch-screen control panel are provided for improved operability
and visibility. In addition, environmental performance
is improved by visualizing power consumption and reducing
air consumption.
The new solutions offered by Citizen Machinery contribute
to a sustainable society in a way that benefits all customers.
MAZAK focused on the EV sector at JIMTOF 2024. As
environmental regulations tighten worldwide, the transition
from gasoline-powered vehicles to electric vehicles is accelerating.
This shift requires significant changes in manufacturing
processes. MAZAK is at the forefront, offering innovative
solutions tailored to the needs of electric vehicle production,
transforming automotive manufacturing facilities to meet
these new standards. MAZAK unveiled a new vertical machining
center (FF-400V/30) ideal for lightweight aluminum
die casting and a horizontal machining center (FF-1250H)
specialized in the machining of large aluminum parts.
From around the world
Many European companies also flew the flag at JIMTOF 2024.
For example the German machine manufacturer Roeders,
which is specifically involved in several tool and mold making
projects in Japan, presented itself at a joint booth.
German software company ModuleWorks has brought its
expertise to Japan and embraced the vibrant energy of Tokyo.
ModuleWorks’ innovative solutions are redefining the
future of smart manufacturing, setting new standards for
precision, safety and efficiency. Some of the highlights at
JIMTOF 2024 included:
32 no. 1, March 2025

fairs
news & facts
Visual Trainer: this “as real as it gets” interactive machine tool simulator
turns digital natives into CNC experts. Machine shops use Visual Trainer
to professionally train operators and prove out CNC programs with
zero downtime and no risk to the real machine.
Next Generation Shopfloor Programming (NGSP): NGSP simplifies and
automates repetitive tasks to bridge the productivity gap on the shop floor.
Already in use by leading OEMs, operators of all levels use NGSP to
confidently program complex machining operations with the touch
of a finger.
Real-Time Collision Avoidance: integrated directly into the CNC
control system, ModuleWorks Real-time Collision Avoidance supports
multi-channel machining. It empowers engineers to run complex
operations with the highest levels of precision and process safety.
MDES (Manufacturing Data Exchange Specification): this new
specification enables seamless 3D data transmission to the CNC control,
making it easy to setup a Digital Twin. By utilizing upstream data
within the digital thread, MDES enhances the overall accuracy and
efficiency of machining operations.
Dormer Pramet introduced several innovative tools whose key features
include improved coatings for longer tool life, and optimized geometries
that enable higher cutting speeds and reduced downtime. These tools are designed
to simplify choices, reduce tool inventory, and significantly improve
productivity and accuracy for Japanese manufacturers.
Sodick introduced world premieres of the LSP4040, a linear motor drive
femtosecond laser machine for ultra-fine precision machining of difficult-tocut
materials, and the UX650L linear motor drive machining center.
HIWIN introduced a new torque motor
rotary table at the exibition, equipped with a
water- cooled direct-drive torque motor, builtin
high-rigidity and high-precision bearings,
absolute angle encoders and a powerful braking
system that is faster than a mechanical
split table.
Unlike conventional mechanical indexing
tables the torque motor rotary table is a directdrive
gear. By adopting a structure without
mechanical transmission mechanism such as
worm gear and roller cam of the conventiona
rotary table, the machine wear is greatly
improved, and the stability of processing
accuracy is improved by almost no backlash
during machining.
One can upgrade to a 3+1-axis, 4-axis, 5-axis
processing machine with a Luku motorized
rotary table. It realizes one-nut machining
and contributes to improvement of processing
efficiency and productivity.
BIG DAISHOWA exhibited eight new
tools for the first time, including the SF
Hydraulic Chuck for clamping diameters
3 – 12, a tool holder for different layouts that
can be realized by selecting SF sleeves. And
the SMART DAMPER LARGE BORE, an
anti-vibration boring tool for boring diameters
from 200 – 340 mm with an integrated
slide for anti-vibration performance.
The modular system for rough and finish
boring with integrated damper EWN boring
head 0.005/0 dail. A fine boring tool for boring
diameter 2 ~ 54, with an ultra-precision
boring head with 1 scale 0.005 mm/0
Okamoto introduced the CNC precision
surface grinding machine PSG157CA-iQ and
premiered a new vertical rotary surface grinding
machine, the VRG10DX.
In the evening after a day full of impressions, the view of the colourful
Rainbow Bridge promises some relaxation
With almost 130,000 visitors JIMTOF 2024
attracted a record number of visitors compared
to 2022, thus confirming its reputation
as one of the most important metalworking
trade fairs. The next JIMTOF will take place
October 26 – 31, 2026.
further information: www.jimtof.org
no. 1, March 2025
33

processes
Mastering technical ceramics:
precision ductile CNC machining
Machining ceramics with µm precision is
a challenge that only few companies take on.
LouwersHanique BV has been doing this for decades.
And once again has the precision manufacturer raised
the bar of the high-precision machining of brittle materials
to a new level. The use of the ductile cutting
mode developed by Kern Microtechnik in combination
with the high-end machining center Kern Micro HD
made all the difference.
Jan van Dingenen,
senior production engineer at
LouwersHanique: “With the
ductile cutting mode developed
by Kern and the Kern Micro HD
we found the perfect solution
to meet the high demands
of our customers”
In 2012 the CEOs of “Louwers Glastechniek” and “Pulles &
Hanique” decided to bundle their know-how and merged
as LouwersHanique BV. Known as specialists for processing
technical glass, quartz crystal and technical ceramics the
newly founded company started with 70 employees. Meanwhile
the successful company has roughly 185 employees
and produces demanding parts for customers in many different
industries such as semiconductor, MedTech and the analytical
market.
LouwersHanique has continuously been growing since its
founding. Senior production engineer Jan van Dingenen is
optimistic for the future: “We are working very closely together
with innovative companies that operate in high-tech
markets such as semiconductors. Above all our extensive
knowledge of processing particularly demanding materials is
required”.
The main focus of the Dutch specialists is on manufacturing
high-end mechatronic assemblies such as end
effectors, mirror blocks, isolators, sensor parts and ceramic
housings. “We take pride in manufacturing high-quality
parts, often mission critical, to be integrated in high-tech
systems that make us a valuable partner for our customers”,
explains van Dingenen.
Ceramics have unique advantages
LouwersHanique provides support from the conceptualization
and development stage all the way up to serial production.
Aside from their deep knowledge they can make use
of extensive technical resources to create novel products
like hermetic feedthroughs, 3D printed glass products and
micromachined SIC parts. The highly automated state-of theart
CNC machining technology is combined with advanced
inspection, metrology and cleaning solutions. This is the only
way to ensure consistently flawless quality.
LouwersHanique is specialized in machining ceramics.
“The equipment of our customers is often being used in demanding
environments”, specifies van Dingenen. The single
parts and assemblies can be exposed to strong abrasive forces,
liquids, gases or vacuum and sometimes in combination with
extreme temperatures. “In this case ceramics have a unique
advantage compared to metals or synthetic materials. Silicon
carbide, for example, can be exposed to temperatures of more
than 1200 °C (2192 °F) without losing its chemical integrity
The Kern Micro HD is in the center of production at LouwersHanique;
the most demanding ceramics are being manufactured here
34 no. 1, March 2025

processes
With the ductile cutting mode, floating chips can be cut off of
even the hardest ceramic parts; surface flatness in the µm-area
and surface quality of Ra = 0,2 µm can be achieved
Together happy about the success to be achieved with the
ductile cutting mode and the Kern Micro HD (left to right):
Ronald Braam, production engineer; Berend-Jan Grimmerink,
engineer; Jan van Dingenen, senior production engineer and
John Seuntiëns, programmer
and structure”, explains the engineer. In addition ceramic
materials only emit minimal gas, are highly rigid and have a
very low coefficient of thermal expansion.
Manufacturing is extremely demanding
All these advantages are facing primarily one disadvantage.
The highly precise manufacturing of ceramics, and especially
sintered ceramics, is very demanding. The risks of damages
such as cracks, fractures and similar issues is high. “Of course
this is not accepted by any customer”, shares van Dingenen.
At the same time demands for accuracies and surface quality
have considerably been going up over the past years describes
the engineer: “Today our customers are demanding tolerances
of up to 1 µm and surface flatness of less than 2 µm on a diameter
of 150 mm. At the same time, with some ceramic parts,
we need to achieve a surface quality of less than Ra = 0,2 µm.”
Until recently these demands posed challenges for the manu -
facturing experts at LouwersHanique. Now they no longer
do. In 2023 the team of Jan van Dingenen contacted Kern
sales’ managers Didier Gony and John Snijders from the
Dutch Kern branch and business representative, Encoma B.V
respectively. “Both of them promptly provided us with
highly valuable information.”, shares the engineer. “Furthermore
they swiftly arranged a visit to Kern’s headquarter in
Eschenlohe”.
Here the Dutch experts had the possibility to extensively
test the manufacturing of their material. According to the engineer,
the results clearly exceeded their expectations: “When
we saw what can be achieved with the ductile cutting mode,
LouwersHanique BV, Hapert (Netherlands), …
… has been active for over 70 years and is now part of
IDEX Corporation (US). The company has approximately
185 employees and manufactures mission critical parts
out of technical glass, ceramic materials and combinations
with metal for industries like semiconductors, analytic,
medical-technology and biotechnology.
which was developed by Kern, we knew that we found the
perfect solution for the demands of our customers”.
Perfect solution:
ductile cutting and Kern Micro HD
LouwersHanique traditionally used to rely primarily on
grinding and lapping for ceramics. With the ductile cutting
mode, even the hardest ceramics can now be milled. This
means: special PCD milling tools with geometrically defined
cutting edges allow the extremely brittle material to be
removed with floating chips. “We achieve outstanding surface
qualities with minimal roughness, so that little or no
polishing is required, even in critical areas. This allows us to
increase our efficiency and satisfy even the most demanding
customers”.
For the highly precise manufacturing of LouwersHanique’s
ceramic parts, in addition to the ductile cutting mode
developed by Kern, an extremely process-stable machine is
required. High rigidity and smooth running, a fast-rotating
spindle and resistance to ceramic dust, are basics. All these
features can be found in the Kern Micro HD. The smart axis
arrangement protects the mechanics from abrasive dust, and
the micro-gap hydrostatics ensure a very high rigidity.
The strong 15 kW high-speed spindle of the high-end fiveaxes
machining center reaches up to 42.000 min -1 . This way
jig grinding is an easy task for the Kern Micro HD. Enabling
both grinding with pins and ductile milling with PKD tools
to be performed in a single clamping.
For the senior production engineer, Jan van Dingenen, the
decision to invest in Kern was the right choice. Besides the
outstanding technology, he strongly emphasizes with the
good cooperation of all involved parties, especially with the
CEO of Encoma, John Snijders: “He supported us through
the buying process and was on site when the Kern Micro HD
was installed. Everything went very smooth and we are very
happy to be a member of the Kern family now”.
further information: www.kern-microtechnik.com
no. 1, March 2025
35

machining center
HoverLIGHT: unique damping for machine tools
Fraunhofer Institutes for Machine Tools and
Forming Technology IWU and for Manufacturing
Technology and Advanced Materials Research IFAM
have made a breakthrough in materials research. The
composite material HoverLIGHT sets new standards
for the construction of machine tools: by combining
aluminum foam and particle-filled hollow spheres,
HoverLIGHT achieves an unprecedented combination
of lightness, stiffness and vibration damping.
In a joint project with an industrial partner, the two
Fraunhofer Institutes have demonstrated for the first time
that HoverLIGHT can dampen vibrations in series machines
by a factor of 3. All this comes with a weight saving of 20 %
compared to the original assembly.
The composite material HoverLIGHT has a core made of
aluminum foam with encapsulated hollow spheres (visible in the
cross-section as round openings); the combined damping
effects of foam and particle-filled hollow spheres are
comparable to those of magnesium
Sticks: the drum peel test (DIN 53 295) proves that the
cover sheets and sandwich core form a stable bond
Particle-filled hollow spheres on foamable aluminum
Lighter, more precise – the advantages of
HoverLIGHT
HoverLIGHT is a composite of metal foam and hollow
spheres and can serve as the core of sandwich structures.
This sandwich principle results in a significant weight reduction,
and the HoverLIGHT core guarantees high damping:
the aluminum foam with the integrated hollow spheres
dampens vibrations significantly more than previously
used composite materials, leading to higher precision in
machining and a longer lifetime of the machine. The sandwich
construction also enables significant weight savings,
allowing for higher dynamics in machining processes.
HoverLIGHT adapts to the specific requirements of different
applications.
36 no. 1, March 2025

machining center
Successful application in practice
In a joint project with Chiron Group SE, HoverLIGHT has
been working effectively in the crossbeam of a milling
machine. The results are impressive:
• 20 % weight reduction: the HoverLIGHT crossbeam is
significantly lighter than a comparable assembly
made of conventional materials
• significantly higher damping: vibration damping
increases by a factor of 3, leading to higher precision
and longer tool life
• increased productivity thanks to higher speed and
precision: machines can produce more parts in less time
when equipped with HoverLIGHT crossbeams
Dr.-Ing. Jörg Hohlfeld, responsible for the research area of
metal foam at Fraunhofer IWU: “With HoverLIGHT we have
developed a material that pushes the boundaries of what
is possible in vibration damping. We solve the conflict of
objectives that arises from the inherently contradictory
requirements of a stiff design of modern machine tools, lightweight
moving assemblies, and effective vibration damping.”
All moving components in machine tools, such as machine
slides, are predestined for HoverLIGHT.
The next goal:
attractive manufacturing costs
The researchers are continuously working to improve
HoverLIGHT and expand its range of applications. The goal
is to adapt the properties of the composite material to the
requirements of further applications and to reduce its manufacturing
costs through industrialized processes. The production
of hollow spheres is complex, energy-intensive
and not yet reproducible. A promising approach is to use
simpler and thus cheaper to produce metallic blisters instead
of hollow spheres, as in drug packaging. The Fraunhofer team
is confident this should allow for significant cost reductions
within a few years.
further information: www.iwu.fraunhofer.de
Tube hone designed for
small diameter, long bore applications
4 - 20 mm and lengths up to 1,500 mm, delivering ideal bore
geometry and surface finish. At the heart of the HTE-1600W
is advanced technology that drives superior performance.
Its active 3-axis function control manages stroke positions,
motion control, stone feed, spindle speed and cutting pressure,
resulting in high accuracy and superior bore geometry.
The machine offers 100 % process control with tool overload
protection, preventing tool breakage and ensuring consistent
results.
Sunnen Products Company, a global leader in highprecision
honing, bore sizing and engine rebuilding
equipment highlights its HTE-1600W Tube Hone,
an all-electric precision honing machine designed for
optimal bore geometry and surface finish in small
diameter, long bore applications.
The HTE-1600W sets a new standard in bore finishing for
the firearms and defense, medical, mining and energy industries.
This innovative machine features an all-electric design,
ensuring ease of maintenance and up to 90 % efficiency.
The HTE-1600W excels in processing parts with IDs from
Compared to traditional bore lapping methods, the HTE-
1600W offers significant advantages. It substantially reduces
cycle time, decreasing processing time compared to manual
bore lapping. The machine’s stroke repeatability within
0.006 in (0.15 mm) ensures consistent and precise honing
results. A size lock system with stone wear compensation
maintains accuracy over time and reduces the need for frequent
adjustments.
The HTE-1600W’s design incorporates a one-piece base for
improved performance and cost-effectiveness. Additionally,
the machine’s traveling steady rest provides additional support
for the tooling used with long workpieces, enhancing
versatility.
The machine is compatible with Sunnen MMT and LBT
tools, offering flexibility for various small, long diameter bore
applications.
information: www.sunnen.com
no. 1, March 2025
37

machining center
For more efficient production
The long-established Czech company Wikov enjoys
an excellent reputation worldwide as a manufacturer
of high-quality gears and gear wheels. To meet the
increasing demand in the railroad sector, Wikov relies
on the S41 CNC universal cylindrical grinding machine
from STUDER, increasing its production speed by up
to 60 %.
In the factory’s own Wikov Museum in Hronov,
Czech Republic, legends are lined up one after
the other, polished to a mirror finish: a fiery red
Wikov 7/28 racing car is just one of the gems.
Like all the other classic cars here, it is adorned
with the iconic Wikov logo with the hammercarrying
worker. Anyone looking at these impressive
engineering achievements from the first third of the 20 th century
will understand why Wikov is known as the “Czech
Rolls-Royce”. However the main business of the company
“Wichterle & Kovářík”, founded in 1918, was the production of
agricultural machinery, making it the largest Czech factory
in this field.
This proud history is still part of the Wikov Group, including
other traditional Czech brands. Today, with over 1,000
employees and several locations, Wikov is a leading manufacturer
of high-quality mechanical gearboxes and gears for
the industry. The plant in Hronov mainly produces gearboxes
for the railroad sector and is the Group’s largest production
site with around 400 employees.
S41 makes production at Wikov up to 60 % faster
One of these employees is grinder Jaromir Hornych. His
blue work suit is also adorned with the Wikov logo and he
is standing just a dozen steps from the automobile museum
in a state-of-the-art production hall. Behind him is a powerful
CNC universal cylindrical grinding machine of the latest
Wikov has its roots in automotive
generation from Switzerland: the S41 from STUDER. He has
used it to machine a pinion gear for a railroad gear shaft and
is now inspecting the shiny piece of metal. “The precision and
surface quality is outstanding, and in such a short machining
time”, says Hornych as he checks important production data
on the large 24-inch touchscreen. Thanks to the revolutionary
C.O.R.E. hardware and software architecture and STUDER’s
own software, working with the S41 is modern and intuitive.
Efficiency, precision, flexibility and future viability through
proven quality and modern technologies were the main
reasons why Wikov decided to invest in a new S41 from
STUDER. “By using the S41, we were able to significantly
speed up the grinding process with high process stability, in
some cases by over 60 % per component”, explains Dominik
Sádlo, who heads the technology department at Wikov. In
addition many machining processes can now be carried out
in a single operation instead of several individual steps as was
previously the case.
With center distances of 1,000 / 1,600 mm (39.4/63 inches),
center heights of 225 / 275 mm (8.85/10.8 inches), and a
maximum workpiece weight of 250 kg (550 lbs), the S41
is one of the largest machines in the STUDER portfolio.
However, Wikov uses it for the production of its smaller
components – after all, it is used for gearboxes for large railroad
vehicles. “Our order situation has increased significantly
in recent years and we were looking for a more flexible and
productive grinding machine, especially for the production
of smaller gear components in large quantities. The S41 was
the best choice due to its high universality, quality and short
set-up times”, says Sádlo.
Dominik Sádlo, head of technology department (Wikov);
Pavel Branda, area sales manager Czech Republic (STUDER);
Jaromir Hornych – grinder at Wikov (left to right)
Proven quality components and
innovative grinding technology
The many advantages of the S41 are the result of STUDER’s
extensive know-how. Like Wikov, the Swiss manufacturer
of quality grinding machines is a traditional international
38 no. 1, March 2025

machining center
Gears
Gear shafts
company with over 111 years of history. Many components
in the S41 have been developed and continuously optimized
in-house. These include the high-precision, wearresistant
StuderGuide® guide system in the cross and longitudinal
slides, the configurable wheelhead with integrated
B-axis with up to four grinding wheels for complete machining
in the same set-up and the patented Granitan® mineral cast
machine bed with its excellent thermal and damping properties.
STUDER is also one of the world’s leading innovators
in grinding machine technology for even more efficient, precise
and resource-saving production. The market-leading
innovation technologies available for the S41 include, for example,
SmartJet® cooling for up to 50 % less energy and water
consumption or the WireDress® process for more precise and
economical dressing of metal-bonded grinding wheels at full
working speed.’
STUDER has also a special development focus on automa
tion. “Automation capability was an important factor for us
when selecting machines, because this topic will be even
more relevant for us in the future”, emphasizes Wikov’s head
of technology Sádlo. As in many industrialized countries,
the shortage of skilled workers is becoming more acute in
The S41 at a glance
hardware:
■ StuderGuide ® guide system with linear drive Turret
wheelhead with direct drive and 0.00005 ° resolution
■ complete machining with up to four grinding wheels
■ C-axis workhead for form and thread grinding
■ C.O.R.E. panel
■ manual control unit (PCU) for setting up close to
the grinding process
■ full enclosure with two sliding doors
■ machine bed made of Granitan ® S103 mineral casting
software:
■ C.O.R.E. OS operating system
■ simple operation and programming thanks to StuderWIN
■ StuderTechnology with integrated expert know-how
■ short set-up and changeover times with STUDER QuickSet
■ standardized interfaces for loaders and peripheral devices
■ external programming station with all machine software
options in StuderWINprogramming
the Czech Republic and night shifts are already difficult to fill
due to a lack of personnel. Intelligent automation is the only
way to maintain or even increase production in the long term
without compromising quality. With easyLoad, STUDER
offers a particularly cost-effective standardized automation
so lu tion for the S41. This gantry loader system with a V-gripper
can handle a wide range of parts and makes workpieces
easily available. It is operated via the machine control system
and no robot programming knowledge is required. Customerspecific
automation solutions are also possible.
Competent customer care in the local language
“Despite all the technology, one thing should not be for gotten:
the focus for us is always on people”, says Pavel Branda,
STUDER area sales manager for the Czech Republic, Slovakia
and Hungary. He is responsible for technical sales in the
region. Branda provided Wikov with expert advice when the
company purchased the S41 and is still in regular contact
with his customer for all questions. “The excellent customer
care in our local language is a major advantage of STUDER.
This aspect is particularly important in the initial phase of
technology introduction”, explains Sádlo. After all, modern
cylindrical grinding differs from other production processes.
“At STUDER we were able to learn from competent experts
how to achieve the desired results with the S41 for our specific
components. Cylindrical grinding at Wikov is now on a
whole new level.”
“In addition to the optimal configuration and installation of
the S41 it was very important for us to train the operators so
that they can use all of the machine’s capabilities efficiently
and achieve optimal grinding results”, confirms Branda.
Wikov grinder Jaromir Hornych also traveled to the STUDER
training center in Thun, Switzerland, specifically for this
purpose. Later an in-depth follow-up training session was
held at Wikov in Hronov. “We were pleasantly surprised at
how quickly our people learned at STUDER how to operate
the S41 and achieve high-quality grinding results”, says
head of technology Sádlo, adding: “The S41 and the cooperation
with STUDER have brought our production to a better
level and this is making a significant contribution to Wikov’s
continued success.”
further information: www.studer.com
no. 1, March 2025
39

machining center
Designed for production
Following the successful introduction of the F 5000
and F 6000 models HELLER is now extending its new
generation 5-axis range at the top end with the F 8000.
With numerous innovations ensuring extremely high
performance and precision, as well as a small footprint,
the F 8000 is suitable for applications in a wide range
of industries. The new high-performance machining
center is on the market since September 2024.
Things move fast at HELLER: autumn 2023, the Nürtingenbased
machine manufacturer unveiled the F 6000, the first
5-axis machining center in its new generation F series. Only
six months later another model was launched: the F 5000.
And the larger F 8000 has been available since AMB 2024 in
Stuttgart. Like its ‘siblings’ the machine is suitable for a wide
range of users in many industries, from mechanical engineering
and power generation to aerospace – from single-part
manufacturing through to flexible 24/7 series production.
The F 8000 is based on the successful 5-axis F series, which
has been on the market for more than a decade. However it
surpasses its predecessors in many areas. For example, with
a width of 4.20 m it has a much narrower footprint and the
basic version takes up about 25 % less space. In addition the
optional PRO version offers the best technical specifications.
Axis acceleration in X/Y/Z has been increased by 50 % to
6 m/s 2 . Chip-to-chip time has been reduced by approx. 30 %. The
F 8000 with PRO package also offers greater precision. Positioning
tolerances in X/Y/Z are 6 µm – a 25 % improvement
over the previous model.
Another advantage of the new F 8000 is its large work envelope
(X/Y/Z: 1,400/1,200/1,400 mm), which allows larger
work pieces to be machined and, above all, the 150 mm longer
stroke in the X-axis, which provides even greater machining
flexibility. In addition to 800 x 800 mm pallets, it is also possible
to use larger 1,000 x 1,000 mm pallets. Head of development
Dr. Manuel Gerst explained: “The maximum pallet load
is 2,000 kg. And from the end of 2024 on, we will offer an
optional pallet load of up to 3,000 kg.”
Full compatibility with the previous generation
To make the transition to the new generation F series as easy
as possible, HELLER has ensured maximum consistency.
This means, for example, that the pallets and tools are fully
compatible with the previous 5-axis range. The new machine
is equipped with the latest generation Siemens control system,
SINUMERIK ONE. However users can easily adopt all NC
programs used on previous machines equipped with Siemens’
SINUMERIK 840D sl control. A main operating unit in console-design
with a 24-inch touch screen and a host of other
features makes the new control system even more enjoyable
to work with.
With the new F series HELLER not only guarantees full
continuity with previous generations. The developers have
also ensured a high level of compatibility with the new
H series 4-axis machining centers. Pallets and tools are interchangeable,
and standardization of structural components
such as beds and columns enables the same strokes, pallet
loads and part dimensions.
40 no. 1, March 2025

machining center
Small footprint provides more space
for automated machining
The standardization of the 5-axis machine within the
range goes even further. The F 8000 uses the same modular
system as the entire F series for key components such as
heads, spindles and tool magazines. The machine structure is
also stan dard ized across the F series, resulting in the narrow
footprint mentioned before. Equally important to the compact
design of the new F 8000 are HELLER’s new rack-type
tool storage systems. They are almost two meters narrower
than the previous versions. This is particularly useful when
automat ing multiple machining centers. Now four machines
can be placed in a row where previously only three could
be installed.
Machining units with tilt and swivel kinematics
Among the highlights of the F 8000 – and the new F series as
a whole – are the completely redesigned swivel heads, which
ensure maximum cutting performance. The integrated motor
spindles, developed in-house, are manufactured by HELLER.
Equipped with an HSK-A 100 interface as standard, the
Dynamic Cutting Universal (DCU) unit achieves torques of
400 Nm and speeds of 12,000 rpm. The Speed Cutting Unit
(SCU) provides 15,000 rpm with HSK-A 100. In conjunction
with the optional HSK-A 63 tool interface, HELLER also
offers spindles with speeds up to 18,000 rpm. For ultra-heavy
machining, the Power Cutting Universal (PCU) unit with
gear spindle is still available – delivering 1,146 Nm of torque
and speeds up to 8,000 rpm.
In addition to the swivel heads HELLER also offers a tilt
head variant for the F 8000. It is characterized by a particularly
high degree of flexibility in 5-axis machining. The tilt
kinematics make it possible to produce the recesses and
undercuts required, for example, in the manufacture of integral
components for the aerospace industry.
Ready for any type of automation
Whether it is for the manufacture of single parts or flexible
series production, the F 8000 5-axis machining center is always
the right choice. For those who are not yet sure whether
they want to equip the machine with pallet automation at the
time of purchase, HELLER offers the ‘Automation-READY’
option for maximum flexibility, meaning that the available
standardized automation systems can be integrated quickly
and easily later. The F 8000 is equipped with an automatic
pallet changer as standard. In addition, extended automation
with linear or rotary storage systems or robots is available.
All in one – milling, turning and other technologies
In addition to automation complete machining is playing an
increasingly important role in many manufacturing companies.
Following this all-in-one concept, HELLER offers an
optional mill-turn function for combined milling and turning
operations for the entire F series. At its heart is the hightorque
DDT (Direct Drive Turning) rotary table. This means
that in addition to milling and drilling, external and internal
contours can be turned longitudinally or transversely
in a single set-up, as well as a wide variety of undercuts and
recesses. Even cutting of external and internal threads is
possible. This eliminates the need for reclamping on separate
turning machines, improving part accuracy and reducing
cycle times.
information: www.heller.biz
no. 1, March 2025
41

machining center
Double the power for machining
large light metal workpieces
Schwäbische Werkzeugmaschinen GmbH (SW)
is strengthening its portfolio of multi-spindle CNC
machining centers with the introduction of the new
BA space3-22 two-spindle machining center.
This further development of the proven space series is designed
for the precise and efficient machining of particularly
large light metal workpieces, such as those increasingly used
in the automotive and aerospace industries. Flexible, robust
and wear-resistant, the BA space3-22 offers short machining
times even for complex components.
SW launched the single-spindle version of the BA space3 in
2020. Since then it has been used primarily in the field of e-mobility.
To achieve even greater efficiency SW’s experts soon
began developing the two-spindle version. This is particularly
suitable for demanding manufacturing processes such
as giga-casting or machining other complex components in
the automotive and aerospace industries. With the introduction
of the BA space3-22, SW is fulfilling its own claim to offer
all machines in a multi-spindle version.
Increased productivity and flexibility
The BA space3-22 is currently the largest machine in the SW
portfolio. Its independent horizontal spindle arrangement
enables two machining scenarios: simultaneous machining
of two parts by two spindles, or the use of both spindles on
one large workpiece. This flexibility is particularly valuable
in series production, where maximum machine utilization
is crucial. The benefits are clear: parallel machining reduces
significantly production times and increases output. Markus
Löhe, aerospace key account at SW, explains: “In a nutshell,
two-spindle machines double the output. The machine can
be used as a conventional two-person machine or, for very
large components, it can easily be configured as a one-person
machine with an even larger machining area.”
Michael Kreuzberger (product manager), and
Markus Löhe (key account aerospace); left to right
The horizontal spindle arrangement allows simultaneous
machining of two components or the use of both spindles
on a single large workpiece
The BA Space3-22 is ideal for machining large workpieces
such as wing ribs
Maximum performance from powerful engines
At the heart of the BA space3-22 are powerful linear and
torque motors. In this combination the advantages of both
motor types are exploited to the full: linear motors guarantee
very fast and precise linear movements, while torque motors
provide dynamic rotary movements. This allows the machine
to achieve maximum acceleration and minimizes not
only machining time but also downtime during tool change
and positioning. “As the linear drives have no mechanical
transmission elements there is also less wear. This results in
longer tool life and lower maintenance costs. Our two-spindle
machines offer twice the productivity per unit area. The
rapid feed rate of the BA space3-22 is 120 m/min compared
to 70 - 80 m/min for the competition. The second spindle significantly
increases the productivity of the machine and thus
improves the throughput considerably”, says Markus Löhe.
Typical for all SW machines: the BA space3-22 combines
stability and precision through its intelligent design. The
combination of box-in-box construction and a monoblock
machine frame ensures thermal stability, reduces vibrations
and thus enables precise machining of even large workpieces.
Generous access to the loading side also facilitates the use
of automation solutions such as robots.
42 no. 1, March 2025

machining center
Precision and flexibility in the manufacture of
complex components for the aerospace industry
Users in the automotive and aerospace industries in particular
will benefit from the dynamic system configuration and
high precision of the machining center. The BA space3-22 is
designed for complex components," says Michael Kreuzberger,
product manager at SW. In the field of electromobility frequent
tool changes often result in long non-productive times.
The dynamics and dual-spindle design of the BA space3-22
save a lot of time. In the aerospace industry, for example, this
machine enables efficient pocket milling with high precision.
The machine is not only optimized for standard processes
but also offers flexibility to machine demanding geometries
(simultaneously). With the 2-axis swivel head, complex workpieces
can be machined in five-axes in a single set-up. This
makes the BA space3-22 particularly suitable for machining
large aluminum structures, for the precise production of
demanding components for battery housings, structural
components or components for aircraft structures. “In the
aerospace industry the precision machining of wing ribs
made from high-strength aluminum alloys with a strength
of 500 MPa is a prime example of the demands placed on
modern CNC machines”, explains Markus Löhe. To achieve
the required strength at the lowest possible weight, these components
are often milled from solid material. The BA space3
can efficiently handle this demanding machining.
BA space3-22 at AMB 2024
The BA space3-22 made its debut at AMB 2024. “The feedback
from these first presentations confirms the demand in
the market”, concludes Michael Kreuzberger. “With the BA
space3-22 we offer a solution that meets the current demands
of the automotive and aerospace industries for efficiency and
easy scalability”.
information: www.sw-machines.com
Taking plate cutting to the next level
IMA Schelling Precision is responding to the increasing
demands being placed on aluminum processing
by launching a pair of new automation solutions:
the AMD.work and HP.stack.
These smart handling systems allow customers to streamline
their cut-to-size operations for heavy aluminum plates
and reduce their dependence on skilled labor, while increasing
the quality and precision of their products. The innovative
systems from IMA Schelling Precision can be flexibly
adapted to each customer’s unique circumstances and can
be expanded as required. AMD.work is the first step towards
fully automated production. Specially designed for use on
the saw, this unit is capable of taking over all the handling
work for the operator. It does so by removing the cut strips
from the cutting line, accurately depositing them and then
reinserting them for the transverse cut. In the final step the
system discharges the finished strips via a conveyor line. The
handling unit can be combined with the fm8, fm10 and fm12
cut-to-size saws from IMA Schelling Precision.
Flexible and versatile –
the HP.stack handling gantry
The HP.stack solution from IMA Schelling Precision kicks off
the second stage of automation. The handling gantry can be
located next to the saw, where it takes over a wide range of
tasks. In addition to feeding the saw with aluminum plates
By introducing the
AMD.work and HP.stack
automation solutions,
IMA Schelling Precision
is responding to the
increasing demands of
the aluminum processing
industry
directly from a cassette, HP.stack can also pick up the
finished blanks from a roller track or conveyor and deposit
them on a different conveyor line, in boxes or on pallets. And
the best part is that the system can be placed directly next to
the discharge aisle at a warehouse.
The gantry can accommodate several suction tools in order
to handle both large plates weighing up to 3,000 kg
as well as the smallest blanks measuring just 50 x 50 mm.
The system is even able to return remainder plates back
to the warehouse. Like AMD.work, HP.stack can be used
in combination with the fm8, fm10 and fm12 saws from
IMA Schelling Precision.
information: www.imaschelling.com
no. 1, March 2025
43

machining center
Precision manufacturing of
high performance transmission components on
vertical pick-up turning machines
Zoerkler Gears GmbH & Co KG, a renowned
manu facturer of high-precision drive systems for the
aerospace and automotive industries, is using the VL 6
vertical pick-up turning machine from EMAG for
machining high-precision transmission components.
This strategic investment underlines Zoerkler’s commitment
to innovation and top quality in the production of complex
drive components. Zoerkler can look back on almost 120
years of history and has developed from a mechanical
engineers’ workshop into an innovation leader in the manufacture
of high-performance gearboxes. Today the company
employs about 100 people, including eight trainees and
15 highly qualified design engineers, and specializes in
the design, manufacture and testing of drive systems for
high-performance automobiles, helicopters and airplanes.
The decision in favor of the EMAG VL 6 was based on the
need for automated machining of heavier components with
the highest precision and reliability. Bernhard Wagner, managing
director of the company, explains: “The VL 6 enables us
to produce complex components with excellent dimensional
accuracy, even with frequent changes of workpieces for our
small series. This is crucial for our production flexibility and
for meeting the high quality requirements of our customers
in the aviation and automotive industries.”
The machine’s integrated hard turning and milling functions
are particularly noteworthy. This multifunctionality
enables Zoerkler to perform demanding machining steps in
a single setup, which contributes significantly to increasing
precision and shortening cycle times.
The impressive helicopter gearbox test stand from Zoerkler
Another advantage of the VL 6 is its highly developed automation
system. “We can often run the machine autonomously
in second and third shifts, which significantly increases our
productivity“, explains Wagner. The combination of reliable
automation and constant precision enables efficient production
around the clock without compromising on quality.
The integration of the VL 6 complements Zoerkler’s impressive
machine park with production technologies such as
turning, milling, grinding, gear cutting, tooth cutting, bevel
gear grinding and eroding as well as testing facilities. The
company has a high-performance test stand for helicopter
gearboxes with an output of up to 2 x 4 MW as well as special
test stands for e-mobility applications. This equipment under
lines Zoerkler’s ability not only to manufacture complex
drive systems, but also to test and optimize them under
realistic conditions.
Zoerkler’s expertize covers a wide range of gearing technologies,
including the manufacture of internal gears, gear rims
and bevel gears for helicopters. The company is particularly
proud of its expertise in producing bevel gear ratios not
equal to 90 ° – a specialty that is highly valued in the aviation
industry.
High-precision machining of a gearbox housing
on an EMAG VL 6
The successful integration of the VL 6 into Zoerkler’s
production processes underlines the company’s commitment
to continuous innovation and quality improvement. This investment
consolidates Zoerkler’s position as a technology
leader in the manufacture of precision drives and prepares
the company for future challenges in the rapidly evolving
mobility industry.
information: www.emag.com
44 no. 1, March 2025

components
Superior performance on 5-axes
The motion control experts at Aerotech present the
AGV5D, an innovative 5-axis laser precession scanner
specially developed for laser micromachining. The
combination of scanner and 5-axis laser motion system
makes it possible to create high-precision bores, contoured
slots and other complex geometries with dimen -
sional tolerances in the sub-micrometer range.
“With its advanced design and versatile programming options,
the AGV5D system sets new standards in laser micromachining
and offers an ideal solution for industries that
require flexibility and long-term precision”, says Simon Smith,
European director at Aerotech. “The special design significantly
minimizes thermal drift during the machining process
– a crucial aspect for long-term accuracy.”
Innovative control approach for
complex boron and milling processes
By combining precise linear motion axes and advanced control
technology, the AGV5D offers complete control over the
entire micromachining process, including laser, scan head
and workpiece positioning. This G-code based approach enables
the integration of standard CAM software, significantly
expanding the range of applications. The AGV5D works in a
similar way to a 5-axis CNC machining center, but uses the
advantages of laser processing for maximum precision and
flexibility. By utilizing a single control system, smooth coordi
nation between the movements of the laser beam and workpiece
positioning is achieved, ensuring a consistently high
quality of machined parts and a simplified programming.
How the 5-axis laser movement system works
The AGV5D uses RS-274 compliant G-code commands to
steer the laser beam along 2D and 3D paths such as lines and
arcs. The beam is directed through a nozzle at the lowest
point of the scan head so that the working volume in which
the laser processing takes place is below this nozzle. The
paths programmed for the X-, Y-, Z-, A- and C-axes move the
focussed point within this working volume. In addition to
beam guidance in five degrees of freedom (DOF), the system
also controls external X-, Y- and Z-axes that position the
work piece under the scan head to extend the field of view and
synchronize the movements with the beam path. Aerotech’s
Automation1 software-based machine control (iSMC) monitors
the entire system and coordinates the G-code trajectories
with the powerful Aeroscript programming commands.
Simon Smith points out: “Automation1 is much more
than a programming tool – it is a comprehensive automation
platform with advanced data visualization and process optimization
functions that are standard in modern motion
control systems for servo tables.”
Precise microlaser processing is particularly in demand
in medical technology, microelectronics and component
production in the automotive industry; the AGV5D 5-axis
precession scanner is optimally designed for this
The ability to optimize parameters and simulate movements
in both the virtual controller and the real hardware
provides users with precise insights into the executed movement
sequences and the control of the laser pulses.
Optimized design for high throughput
without compromise
To ensure optimum thermal stability the AGV5D contains no
electronics in the scan head, which minimizes heat transfer
and thermal drift. The actively water-cooled motors provide
additional stability during longer machining operations. The
scan head operates with air sealing to minimize dust ingress,
while the scan mirrors and optics are cooled by direct gas
purging. These measures improve the repeatability and
reproducibility of the machining results, which leads to a
consistently high quality of the manufactured parts.
Pioneering in many industries
5-axis laser precession scanners play a crucial role in laser
micromachining, as they enable the production of vertical
sidewalls for high aspect ratio tasks, among other things.
This capability is essential for precision applications that
require complex geometries and tight tolerances. Simon
Smith emphasizes: “With our technology industries that
demand exceptional accuracy and detail can make significant
progress.” According to Aerotech, applications range from
the production of medical devices such as cardiovascular
implants to microelectronics processing and the manufacture
of precision parts for the automotive industry.
further information: www.aerotech.com
no. 1, March 2025
45

components
ModuleWorks releases
2024.12 software components
ModuleWorks announces the 2024.12 release of its
software components for digital manufacturing and
digital factory.
This latest release of the ModuleWorks SDK includes various
new and enhanced features aimed at increasing safety, toolpath
generation efficiency and part quality. These features
contain enhancements across multiple components, ranging
from multi-axis surface finishing to simulation and many
more.
tool during operation. In the 2024.12 release, 3+2-axis deburring
has been improved to provide 3+2 orientation with
minimum 5-axis motion. As a result users benefit from
enhanced machining safety and accuracy.
Multi-axis surface finishing –
SWARF machining accurate 4-axis SWARF mode
The 4-axis SWARF mode has been significantly enhanced
to achieve optimal geometric accuracy. This improvement
addresses the challenge of machining complex surfaces, such
as cylindrical cams, using flank milling on a cost-effec tive
4-axis machine. Traditionally, aligning the tool with the surfaces
when using a tool smaller than the slot, has been difficult.
However, the new algorithm now accounts for kinematic
limitations during the initial toolpath calculation, eliminating
the need for 4-axis enforcement in post-processing and
reducing the risk of inaccuracies.
With the ModuleWorks 2024.12 release this enhancement
brings several benefits, including improved accuracy of parts,
reduced machining costs and greater flexibility in selecting
tool diameters. By addressing these challenges the new 4-axis
SWARF mode enhances precision and cost-effectiveness in
machining, making it a valuable upgrade for manufacturers.
3-axis machining automatic
machining area for barrel tools
During 3-axis finishing users often struggle to manually
identify and define the areas that can be machined by the
different sections of the barrel tools. This can result in significant
increases in both programming and machining cycle
times.
A new feature in ModuleWorks 2024.12 assists users by
automatically identifying the steep and shallow areas on the
part. This enables optimal use of the range of barrel tools, reducing
cycle times for finishing and improving surface quality.
Multi-axis edge finishing –
deburring consolidated 3+2 behaviour
Until now it was difficult for users to eliminate all the simultaneous
5-axis moves from a 3+2-axis deburring toolpath.
This would result in unpredictable motion on the machine
3-axis machining rest finish
based on previous tool shaft length
In previous releases, creating a rest finish operation with a
long tool was difficult when the part had been partially machined
using the same tool with a shorter stick-out.
46 no. 1, March 2025

components
The ModuleWorks 2024.12 release introduces a new option
that automatically detects the areas left by the previous short
tool. This enables efficient machining with a longer tool stickout.
It assists users by automatically detecting the rest regions.
Users can also apply more specific cutting conditions to each
operation to improve the surface quality.
Users often struggle to achieve optimal triangulation due
to the need to balance performance and stock quality. For
very large and complex stock models, simulation responsiveness
can be poor, leading to significant delays on the
shop floor.
The ModuleWorks 2024.12 release solves this problem
through a new triangulation method based on a dexel model.
This new method delivers significantly faster stock drawing
and mesh exports, resulting in improved simulation performance.
In addition the new triangulation improves the
watertightness of exported meshes.
ModuleWorks 2024.12 is available for download from the
ModuleWorks website.
further information: www.moduleworks.com
A familiar face in a new position
After more than 15 years of working as the country
manager of India for SolidCAM, Amod Onkar joins
ModuleWorks as the new global head of marketing.
With over 25 years of experience in CAD/CAM and
CNC machining, Amod brings an impressive track
record of strategic business development, team leadership
and industry innovation to his new role.
Amod played a pivotal role in shaping the CAM landscape
in India. Under his leadership SolidCAM grew from having
just two customers to over 1,200, consistently achieving a
year-over-year growth rate of 20 % in the past five years. He
built and managed a high-performance team of 72 engineers
and sales professionals across multiple locations while spearheading
technical advancements in 3- and 5-axis milling.
His extensive experience includes integrating ModuleWorks’
toolpath engines into SolidCAM products, a proof to his deep
understanding of the technology that drives advanced machining
solutions.
Beyond business development Amod is known for his ability
to foster innovation, build global training programs and
scale technical teams. His experience in product strategy,
global market expansion and reseller network development
will be instrumental in shaping ModuleWorks’ future marketing
efforts.
Amod Onkar is the new global Head of Marketing in India
The company’s decision has been made in light of several
years of successful cooperation: “I have known Amod
for the past 20 years and could appreciate his work the
whole time, especially his deep knowledge of CAM”, says
Yavuz Murtezaoglu, managing director and founder of
ModuleWorks.
further information: www.moduleworks.com
no. 1, March 2025
47

components
More value from coolant
Ultra-fine filtration at the highest efficiency level
reduce operating costs sustainably with modern
Vomat air conditioning technology. Maximum precision
grinding in industrial metalworking requires
state-of-the-art grinding, measuring and peripheral
technologies.
Metalworkers such as tool manufacturers must always be
technically up to date and all process parameters must be
perfectly coordinated. The ultra-fine filtration of cooling lubricants
is a decisive factor in the overall machining system.
On the one hand, clean coolants significantly improve the
quality of the ground workpieces, and on the other hand, fine
filtration extends the service life of the grinding oils, which
contributes to considerable savings in production costs. At
INTEC in Leipzig filter manufacturer Vomat from Treuen
will be showcasing options for customized concepts for the
filtration of cooling lubricants and their temperature control.
Steffen Strobel, technical sales manager at Vomat: “In modern
metalworking, high-performance coolant filtration is much
more than just filtering an auxiliary material. Particularly
when using innovative grinding oils, it is essential to meet
the highest demands for ultra-fine filtration. Choosing the
right filter system – whether for carbides (HM), high-speed
steels (HSS) or a combination – is a key factor for the quality
and efficiency of the entire production process. The full
potential of modern cooling lubricants can only be exploited
through the use of modern ultra-fine filtration technologies,
which sustainably optimizes added value.”
The filter manufacturer Vomat will be presenting at
INTEC in Leipzig, hall 3, booth B40, options for
customized concepts for the filtration of cooling lubricants
and their temperature control
In addition to the energy-efficient, resource-saving
coolant ultrafine filtration technology, the Vomat
LBG air conditioning system for entire production halls
will also be an important topic at INTEC
Thanks to their special design features, Vomat filters are
ideally placed to filter even the latest generations of cooling
lubricants reliably and cost-effectively. With special high-performance
precoat filters, full-flow filtration ensures 100 %
separation of dirty and clean oil, so the system permanently
provides the grinding system with clean oil in NAS 7 quality
(3-5 μm). Another advantage is the energy efficiency of Vomat
technology: Vomat systems filter and flush as required. This
means that the back-wash cycles are controlled depending on
the degree of contamination of the filter elements.
Fully automatic dosing and protection of
water-miscible cooling lubricants
The Vomat MDS system for the fully automatic dosing, mixing
and maintenance of water-miscible cooling lubricants
will also be shown at INTEC. MDS ensures the correct dosing
and mixing of water and concentrate fully automatically
before and during use, detects contaminants during the process
and extracts them. A special distribution unit also allows
several grinding machines to be connected. Energy-efficient
cooling and heating of production halls additionally
to energy-efficient, resource-saving coolant ultrafine filtration
technology, the Vomat LBG air conditioning system
for entire production halls will also be an important topic at
the INTEC trade fair stand. Steffen Strobel: “Air conditioning
technology is a special topic in connection with cooling lubricoolant
cooling. Based on this expertise our engineers have
developed a new air conditioning unit that converts excess
energy from production and peripheral machines, such as
grinding machines, oil extraction systems, machine pumps,
etc., and can then heat or cool the production hall via the air
conditioning ducts with an accuracy of +/- 1° C.”
further information: www.vomat.de
48 no. 1, March 2025

components
Digital technologies for
efficient automation at every level
“Pioneering innovation and productivity – empowering
your success!” is SCHUNK’s motto for this year’s
Hannover Messe. Visitors can experience firsthand
how innovative automation concepts and AI-driven
digital services enhance productivity. These technologies
are key to efficient, resource-saving, and futureproof
manufacturing. The world’s leading industrial
trade show takes place from March 31 to April 4, 2025.
More than ever, today’s challenges require companies to
adopt a solid strategy to secure their long-term competitiveness.
As a trusted partner, SCHUNK not only delivers innovative
automation concepts to boost productivity but also
drives the digital evolution of its portfolio. The technology
pioneer follows a comprehensive, collaborative technology
strategy to enable flexible, future-oriented automation in any
environment and at any level of digitalization – today and in
the future.
Easy-to-use on a platform
In the SCHUNK control center users always have full transparency
over their process steps. Here the latest mechatronic
SCHUNK grippers can be digitally commissioned, monitored
and adjusted as needed. The family includes the EZU
centric gripper, EGU parallel gripper and EKG electric
gripper for small components. These grippers offer a wide
range of communication interfaces, PLC function blocks and
plugins for various robot manufacturers. Additionally the
con trol center provides extended configuration options and
regular software updates, enabling users to unlock the grippers’
full potential. This forward-looking platform is set to be
gradually expanded to all SCHUNK products.
Shared data creates value for everyone
When developing its digital building blocks SCHUNK follows
an open, user-centric approach. To this end, the company
provides open-source software for its new grippers on
open platforms such as GitHub and ROS, making it accessible
for further development and expanding the range of
applications. Significant potential lies not only in industrial
robotics, but also in cobots and humanoid robotics, which
can be used in various environments. To collaboratively unlock
these diverse and complex application areas, SCHUNK
offers its proprietary humanoid SVH 5-finger gripping hand
as open-source software and as a digital twin.
Virtually planned and faster implemented
The digital factory of the future will be planned and optimized
virtually before it takes shape in the real world. Particularly
complex systems can be designed and simulated
more efficiently in the industrial metaverse, reducing time
and effort. For support SCHUNK provides CAD data for
all its 13,000 components, gradually refining them into very
There are great opportunities in humanoid robotics;
SCHUNK will showcase the SVH 5-finger gripping hand
realistic digital twins. The latest mechatronic grippers are
already available as advanced digital twins, replicating not
only communication interfaces but also the physical behavior
of the grippers during movement.
SCHUNK will demonstrate what a virtual industrial process
could look like at Hanover, using the example of a complete
automation cell for battery cell handling in the e-mobility
sector. Developed together with technology partner ISG
the system allows simulation in the ISG virtuos tool. From
there models can be exported directly to the NVDIA
Omniverse, where SCHUNK provides not only its component
libraries, but also complete assemblies and custom automation
solutions to create virtual industrial worlds. Additionally
the AI software for the 2D Grasping Kit, awarded the
HERMES award 2024 for handling unsorted parts, is already
being trained and further developed in the metaverse.
At the fair SCHUNK will demonstrate how a consistent
technology strategy across all levels can drive productivity
and efficiency. Timo Gessmann, CTO of SCHUNK sums it
up: “At SCHUNK our customers are at the heart of all our
innovations. We enhance physical components with digital
solutions to meet customer needs and support efficient automation
at every level – compatible with any ecosystem.”
Connected exhibitor project “battery use-case”
E-mobility is a key topic of the energy transition and industrial
transformation. Exhibitors will come together in the
project “battery use-case” to demonstrate how automated
battery production and sustainable recycling processes
can become a reality through collaborative partnerships.
SCHUNK, together with FANUC, presents automated
process steps for handling prismatic battery cells during
unloading and feeding into a welding system. Visitors can
explore the special exhibition in hall 6, booth D51.
further information: www.schunk.com
no. 1, March 2025
49

components
Production of transmission parts for electric cars
Greater efficiency and precision
Hota Industrial is the largest manufacturer of drive components
in Taiwan. The Taichung-based company now uses the Mando G211
mandrel from Hainbuch for the production of transmission parts
for electric cars.
The material used, a low-alloy case-hardening steel, and the monthly production
volume of 20,000 units place high demands on machines and tools.
The workholding manufacturer from Germany was able to meet the requirements,
resulting in a 20 % increase in productivity.
The collaboration between Hota and Hainbuch began in May 2021. The
gear manufacturer planned to change the clamping situation for all process
steps before hardening in order to achieve higher process reliability and production
quality. The drive gears are manufactured on a Hartech HGH-250
gear hobbing machine. Hartech is the mechanical engineering division of
the Hota Industrial Group. Previously Hota used collets in the production of
helical drive gears. “For our production the collets did not meet the requirements
for concentricity and repeatability”, says Alex Chao, deputy head of
design at Hota Industrial.
Convincing rigidity achieved
The selected Mando G211 mandrel clamps radially with pull-back effect.
Depending on the mandrel size, the radial clamping force of the mandrel is
42 - 150 kN. This extremely rigid I.D. clamping provides the required accuracy.
Integrated flushing channels keep the clamping device free of chips.
The improved process also reduces the machining time per part. The segmented
clamping bushings of the mandrel are vulcanized and thus dampen
vibrations during machining. The service life of the tools has increased
significantly since the mandrel had been installed.
20 % less set-up time
The service life of the mandrel Mando G211 is longer than that of the collets
previously used. “The mandrel with the segmented clamping bushings
offers high concentricity and also a long service life of the vulcanization”,
says Chao, explaining the choice of clamping device.
The handling of the clamping devices has also been simplified for the user:
the G211 with its slim tool runout contour is ideal for gear production. The
maximum length of the mandrel is 213 mm. The vulcanized segmented
clamping bushing also enables a span range from 0.5 mm (clamping range
20 - 28 mm) up to 0.9 mm (clamping range of the mandrel from 69 - 120 mm).
Hota Industrial was founded in 1966 and has grown from a small
family-run workshop to become the largest manufacturer of power
transmission components in Taiwan. With an annual production volume of
20 million components, Hota is a global leader in transmission production,
with only 4 % of products sold domestically and 96 % exported to automotive
manufacturers worldwide. Hartech is the mechanical engineering division of
the HOTA Industrial Group, which has been responsible for the
gear business as a separate division since 2023.
The segmented clamping bushing of the Mando
G211 mandrel is vulcanized and thus dampens
vibrations during machining
This makes it easier to compensate for workpiece
diameter tolerances during work preparation.
The effect of changing to the mandrel
from Hainbuch is a reduction in both set-up
time and machining time by 20 %.
Good service makes all the difference
Selecting the right workholding technology
has significantly improved the entire production
process. The advice provided by Hainbuch
was also an important factor in Alex Chao’s
choice of the workholding manufacturer:
“We are very satisfied with the service and advice
provided by the Hainbuch employees,”
confirms Chao. Compared to other manufacturer’s
products, the Mando G211 mandrel
impressed with its stability, service life and
good price-performance ratio. In the future
Hota plans to introduce the Hainbuch Mando
G211 as an option for all new machines.
further information: www.hainbuch.de
50 no. 1, March 2025

impressum
ISSN 2628-5444
publisher
Benno Keller
phone + 49 (0)911 - 2018 200
fax + 49 (0)911 - 2018 100
keller@harnisch.com
editor-in-chief
Eric Schäfer
phone +49 (0)911 - 504 98 82
fax +49 (0)911 - 506 38 32
eric.schaefer@harnisch.com
managing editor
Christiane Ebner
phone +49 (0)911 - 2018 260
fax +49 (0)911 - 2018 100
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Four issues per year
3M .................................15
Aerotech, Inc. .......................45
CemeCon AG .......................23
CERATIZIT ........................25
EMAG GmbH. ..................... 44
FILL Gesellschaft m.b.H.. .............26
Fraunhofer-Institut für
Werkzeugmaschinen und
Umformtechnik IWU .............. 36
Fritz Studer AG .....................38
Gebr. Heller Maschinenfabrik GmbH . 40
HAINBUCH GMBH SPANNENDE
TECHNIK. . ........................50
IMA Schelling Group GmbH. . ........43
Hartmetall-Werkzeugfabrik
Paul Horn GmbH ..................15
JIMTOF ............................28
KERN Microtechnik GmbH. . .........34
company finder
Lach Diamant Jakob Lach
GmbH & Co. KG ....................6
MAPAL Fabrik für Präzisionswerkzeuge
Dr. Kress KG ......................21
Mikron AG, Division Tool ............10
ModuleWorks GmbH ............ 46, 47
Platinum Tooling Technologies, Inc ....25
pro-micron GmbH ..................26
Schumacher Precision Tools GmbH ...16
SCHUNK SE & Co. KG ..............49
Schwäbische Werkzeugmaschinen
GmbH. .......................... 42
Siemens Aktiengesellschaft .......... 24
SIMTEK Präzisionswerkzeuge GmbH ..19
Sunnen Products Company ...........37
VDW – Verein Deutscher
Werkzeugmaschinenfabriken e.V. ......27
Vomat GmbH ...................... 48
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copyright © 2025 Dr. Harnisch Publications
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Lach Diamant Jakob Lach GmbH & Co. KG ..................................cover
Mikron AG, Division Tool ...................................... inside front cover
no. 1, March 2025
51

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