motion_09-2 - galika

MOTION 

THE CUSTOMER MAGAZINE OF THE SCHLEIFRING GROUP 

Well positioned 

With good strategies and persistence through turbulent times 

MACHINERY IN MILAN: KÖRBER SCHLEIFRING at the EMO 2009 

INDIA: A country of superlatives where all signs point to growth 

KURT A. KÖRBER: The founder of the SCHLEIFRING Group 

ISSUE 2/2009

PROFILE GRINDING 

WITH WINTERTHUR: 

PASSIONATELY PRECISE 

Switzerland 

Winterthur Schleiftechnik AG 

Oberer Deutweg 4 

8411 Winterthur 

Tel.: +41 (0)52 234 41 41 

Fax: +41 (0)52 232 51 01 

wst@rappold-winterthur.com 

Germany 

WENDT GmbH 

Fritz-Wendt-Strasse 1 

40670 Meerbusch 

Tel.: +49 (0)2159 671-0 

Fax: +49 (0)2159 806 24 

info@wendtgroup.de 

USA 

Winterthur Corporation 

10 Viking Road 

Webster MA 01570 

Tel.: +1 (508) 949 10 61 

Fax: +1 (508) 949 20 86 

info@winterthurusa.net 

Austria 

Rappold Winterthur Technologie GmbH 

St. Magdalenerstrasse 85 

9500 Villach 

Tel.: +43 (0)42 42 41 811 0 

Fax: +43 (0)42 42 41 811 701 

office@rappold-winterthur.at 

www.winterthurtechnology.com 

United Kingdom 

Winterthur Technology UK Ltd. 

2 Oakham Drive 

Parkwood Industrial Estate 

Sheffield S3 9QX 

Tel.: +44 (0)114 275 42 11 

Fax: +44 (0)114 275 41 32 

info@winterthurtechnology.co.uk 

Sweden 

SlipNaxos AB 

Folksparksv. 31 

59383 Västervik 

Tel.: +46 (0)490 843 00 

Fax: +46 (0)490 146 00 

support@slipnaxos.se 

Germany 

Winterthur Schleiftechnik GmbH 

Hundsschleestrasse 10 

72766 Reutlingen 

Tel.: +49 (0)7121 93 24 0 

Fax: +49 (0)7121 93 24 24 

info@rappold-winterthur.de

Clever strategies 

Dear Readers, 

During the summer, the world economy has shown 

increasing signs that the downward trend has come 

to an end. This offers a ray of hope, even though the 

crisis continues to have a fi rm grip on virtually all sec- 

tors. The SCHLEIFRING Group too has felt the knock- 

on effect of the downward trend of recent months. 

Nevertheless, we must not lose sight of the whole 

picture. What happens when the economy picks up? 

And what can we do to prepare ourselves for this? 

For the SCHLEIFRING Group this means implementing 

existing strategies further, optimizing production 

processes and maintaining the budget for research 

Yours sincerely 

Dr Ralf Kammermeier 

Managing Director 

Körber Schleifring GmbH 

EDITORIAL 

and development. Innovation should not be taken for 

granted; it is the result of consistent research and 

development – even during turbulent economic times 

like these. This is what the forthcoming EMO in Milan 

is all about, where we are showcasing many new 

products. 

In good tradition, the SCHLEIFRING Group is continuing 

with the entrepreneurial spirit and inventiveness 

of our founder Kurt A. Körber, whose 100th birthday 

we are celebrating this year. 

I hope you enjoy reading this issue of MOTION. 

MOTION 02/09 

3

CONTENTS 

4 MOTION 02/09

NEWS 

06 

06 

COVER STORY 

08 

18 

20 

26 

28 

30 

40 

42 

New collaboration 

WALTER and DMG expand the range of 

tool measuring equipment available 

Accolades 

Presentation of the ‘Award della Meccanica’ 

and the Fritz Studer Award 2008 

Crisis management 

The SCHLEIFRING Group invests in 

long-term strategies and sticks to its 

path towards the future 

TOOLS & TECHNOLOGY 

World class 

Industry supplier Kostwein uses 

SCHAUDT grinding machines 

Electric motor production 

Otto Suhner GmbH replaces six 

machines with the STUDER S242 

Blister packaging 

The BLOHM PLANOMAT HP is used 

in the pharmaceuticals industry 

Sustainable power generation 

Machining turbine buckets on 

MÄGERLE grinding centers 

Tool and mold making 

JUNG is fi rst choice for Söhnergroup 

and Fischer GmbH 

Moving technology 

WALTER software assists with 

grinding artifi cial joints 

Micro tools 

Swiss watch manufacturer IWC 

manufactures its own special tools – 

on the EWAG WS11 

18 

MARKETS & TRENDS 

12 

16 

12 

34 

MOTIONS & MORE 

22 

32 

38 

CONTENTS 

EMO Milan 2009 

SCHLEIFRING Group innovations at 

the leading industry trade show 

Manufacturing quality 

planlauf GmbH specializes in 

machine dynamics with vibration 

phenomena 

Focus on India 

All signs point to growth on the 

dynamic subcontinent 

The creation of the SCHLEIFRING Group 

Kurt A. Körber, inventor, entrepreneur 

and founder 

upgrade Göppingen 

The newly launched JUNG newsletter 

provides information on innovative 

grinding applications 

ReMOTION 

A look back at the SCHLEIFRING 

Grinding Symposium 2009 

IMPRINT 

Publisher: Körber Schleifring GmbH, Hamburg Chief editor: Peter Lütjens Realization: JDB MEDIA GmbH, Schanzenstraße 70, 20357 Hamburg, Deutschland Project management: Jan 

Hawerkamp Art direction: Claudia Schiersch Editorial board: Marc-Oliver Prier (dir.), Lutz Günther, Oliver Haastert, Dania Müller, Ira Schroers Layout: Steffi Pfl ugbeil (dir.), Yvonne Vahland 

Proofreading, editing and translation: SKH SprachKontor Hamburg GmbH Photos: akg-Images (S. 37), augenklick (S. 18), dpa (S. 18), Getty Images (Titel, S. 4, 8, 11, 35, 36, 37), iStockphoto 

(S. 9, 26, 34, 35), Laif Travel (S. 12), Masterfi le (S. 10, 42), Siemens (S. 11, 28), Stockmaritim (S. 18), Ullsteinbild (S. 22), Visum (S. 9, 35), xxpool/Miriam Maslo/Science Photo Library (S. 41) 

Lithography: Fire Dept. GmbH, Hamburg Printing: NEEF + STUMME premium printing GmbH & Co. KG, Wittingen 


5

NEWS 

MARKETING COLLABORATION 

Wider range of products 

To coincide with the start of this year’s EMO in Milan 

(October 5–10, 2009), Walter Maschinenbau GmbH, 

part of the SCHLEIFRING Group, has entered into a 

European marketing collaboration with DMG Microset 

GmbH. This alliance offers customers a unique complete 

tool measurement package. In concrete terms, this means 

that the WALTER product range has been extended by DMG 

Microset tool presetting products. In return, the DMG 

6 MOTION 02/09 

Congratulations: 

STUDER Managing 

Director Fred W. 

Gaegauf (left) 

presents the Fritz 

Studer Award to Dr 

Severin Hannig 

sales organization will also offer WALTER machine tools. 

The collaboration will furthermore include an intensive 

exchange in the area of mutual supply of hardware and 

software components. The benefi t for customers of 

both companies is that from now on, they will have one 

competent point of contact for all equipment concepts. 

Support and service will be provided as before by the relevant 

supplier. 

ACCOLADES 

Two awards have been presented 

great honor for Dr Severin Hannig: the scientist from the Laboratory for Ma- 

A chine Tools and Production Engineering (WZL) of RWTH Aachen was awarded 

the Fritz Studer Award 2008 during the international SCHLEIFRING Grinding Symposium 

2009. Hannig received the prize which is worth 10,000 Swiss francs for his 

work entitled ‘Analysis, modeling and simulation of dynamic behavior in centerless 

plunge grinding’. The research prize is open to graduates of European universities 

and European universities of applied science. Assessment criteria include the application 

of knowledge in the machining industry, innovation and ideas in research 

work, scientifi c content and the accuracy of statements and results. This is the 

second time that STUDER has awarded the prize. The system developed by Dr 

Hannig takes particular account of the dynamic resilience behavior of machines. 

Extensive studies on centerless grinding (see also page 16) have been the main 

focus of his research. 

A fi rst in Italy. The fi rst ‘Award della Meccanica’ prize for engineering was awarded 

in Segrate this spring. The STUDER S22 was awarded the prestigious ‘Premio alla 

Tecnologia’ in the grinding machine category, an acknowledgement of the very 

best in engineering. The jury awarded prizes for a total of fi ve machine types: 

machining centers, lathes and turning centers, grinding machines, transfer machines 

and control systems. 

The award: 

Francesco Buccieri, 

Head of STUDER 

Sales in Italy (left), 

accepts the trophy 

www.studer.com

Meister Abrasives AG · Switzerland · www.meister-abrasives.com 

Meister Abrasives 

Make A Quality Decision International

+COVER STORY 

HANDLING THE CRISIS 

Riding the storm 

Persistent: Using 

good strategies 

and determination 

to keep the end goal 

in sight 

The economic crisis has hit many sectors hard. KÖRBER SCHLEIFRING is investing in a 

long-term strategy and is sticking to its chosen path towards the future. 

ever before has the global econo- 

N my been as interlinked as it is today. 

This applies not only to global trade 

but also to the complex interaction of 

industries. It comes as no surprise that 

such close links are the reason why the 

economy worldwide is suffering the 

consequences of the crisis – with signifi 

cant impact on the target markets of 

the machine tool industry. Capacity uti- 

lization is currently between 50 and 70 


per cent and is thus considerably lower than in the previous year. No investments 

in additional capacities or even replacement investments are being made. 

The automotive industry and its suppliers, for instance, have been hard hit – al- 

beit with regional differences. The biggest losers of the economic crisis are car 

makers in the United States and Japan with a predicted production loss of 37 and 

28 per cent respectively, in 2009 (see chart, top right). The European automotive 

industry is not much better off despite economic stimulus plans. Here, the number 

of cars produced will drop by 20 per cent. China and India, on the other hand, will

Crisis-hit: Like many other sectors, the automotive 

industry is suffering from the economic slump 

be able to show strong growth in the 

current year. Both countries profi t from 

slower yet sustained economic growth 

and with it increasing domestic demand. 

The situation is similar in the manufacturing 

sector. In Germany alone, sales 

have collapsed in record time and have 

fallen by 21 per cent in the fi rst half of 

2009 compared with the previous year. 

Although current economic data indi- 

cate that the downward trend has 

stopped – this does not mean that we 

have weathered the crisis. Take, for example, 

the metal and electronics industry. 

In this sector, demand is still 26 per 

cent below the level of 2008, and production 

25 per cent. 

Mechanical engineering companies 

around the globe are affected by a specifi 

c set of problems. Their goods are 

classed as ‘postponable’ – durable goods 

that companies rely on, but whose pur- 

chase can easily be postponed. Man- 

ufacturers of machine tools are particularly 

affected. According to information 

by the German Machine Tool Builders 

Association (VDW) orders received are 

down by 70 per cent during the fi rst half 

of 2009, compared with 2008. ‘Within a 

year, the level of orders has practically 

been reduced to a third,’ comments Dr 

Wilfried Schäfer, Secretary of VDW. Machine 

tool manufacturers in Japan were 

even worse hit. Their order levels actu- 

GLOBAL CAR PRODUCTION 1 ACCORDING TO REGIONS 

2008 2009 Change 

Europe 20,489.6 16,391.9 –20% 

China 7,492.2 8,943.0 +19% 

Japan/Korea 14,400.9 10,297.5 –28% 

Middle East/Africa 1,718.2 1,516.3 –12% 

North America 12,641.4 8,016.4 –37% 

South America 3,738.4 3,430.1 –8% 

South Asia 4,970.9 4,312.0 –13% 

India 1,930.0 2,100.0 +9% 

Worldwide 65,451.6 52,907.2 –19% 

The automotive industry is one of the major losers of the global economic crisis. 

Except for China and India, production fi gures are falling worldwide. Losses in North 

America, Japan/Korea and in Europe are especially high. 

ally fell by 80 per cent. The SCHLEIFRING Group too has not been unscathed by 

the crisis. ‘We are having to accept a sharp decline in orders but are able to cope 

with it better than some competitors,’ says Dr Ralf Kammermeier, Managing Director 

for Sales and Marketing of Körber Schleifring GmbH. ‘Our broad range of products 

and services means that we are well placed to absorb fl uctuations in indi- 

vidual target markets.’ The international presence of the Group also guarantees 

stability, as the market potential for grinding machines has been affected in varying 

degrees in individual regions of the world (see diagram below). The development 

of stable markets such as wind power, energy turbines and medical technology 

is also helpful. 

� The right reaction to the crisis 

‘With all the drama surrounding the current situation, it is essential to keep a cool 

head. Instead of scaremongering, a consistent and deliberate approach is required,’ 

analyzes Dr Kammermeier. In order 

to sail through the crisis, many 

companies focus on management 

approaches that comprise restruc- 

turing through capacity alignment, 

consolidation of locations and 

cost–cutting programs. These 

methods on their own, however, 

are not enough to emerge stronger 

from the economic slowdown. In 

the medium term, sustainable 

strategies which are also effective 

while the markets are recovering 

will be much more in demand. Flexibility 

plays a central role in this. 

Companies must be in a position 

to follow a growth path in good 

time. This is supported by lean 

process chains and modern 

processing technologies. Short 

2008 

2009 

BIG LOSSES 

America 

– 32 % 

€ bn 

Western Europe 

– 40 % 

Eastern 

Europe 

–36 % 

World Total 

China 

– 12 % 

Declining market potential of grinding 

machines compared to the previous year 

(2008/2009): The development is subject 

to regional differences. 


Asia 

without 

China 

– 38 % 

9 

1 Per thousand. Source: CSM Worldwide, Inc., July 2009 

Source: KÖRBER SCHLEIFRING

COVER STORY 

A promising outlook: After some 

turbulence, experts expect the aircraft 

industry to pick up 

processing times and effi cient logistic 

processes are a prerequisite for a low 

level of working capital, which also helps 

to fi nance growth. An important instru- 

ment for managing processes company 

wide is an effi cient IT infrastructure. All 

this happens for the benefi t of the cus- 

tomer, for innovative pro ducts, global 

presence and effi cient service. KÖRBER 

SCHLEIFRING is acting with foresight 

and with caution. The Group of compa- 

nies is continuing with the existing strat- 

egy and is investing heavily – against the 

general trend. The R&D budget remains 

constant, irrespective of the declining 


turnover. The Group is consistently work- 

ing on the implementation of new pro- 

duction and manufacturing concepts and 

is strengthening its service portfolio. 

� High willingness to invest 

Customers are also profi ting from this 

long-term course. Based on the concept 

for production and manufacturing plants, 

the companies of the SCHLEIFRING Group 

are concentrating the manufacture of ba- 

sic machines on three production sites, 

resulting in more effi cient and standard- 

ized manufacturing processes with short- 

er processing times. The remaining loca- 

tions are able to concentrate exclusively 

on specialized customer applications, 

continuously extending their knowledge 

in these areas and supporting their customers 

with increasing technical competence. 

Examples of the SCHLEIFRING 

Group’s high willingness to invest are the 

opening of a 2,000 sqm building for the 

manufacture of basic machines and the 

commissioning of a new modern highbay 

warehouse at STUDER, doubling the 

assembly capacity at MÄGERLE with a 

new building for cus tomerspecifi c applications 

and the effi cient precision manu- 

facturing facility for local products which 

is being built in China. 

In diffi cult economic situations com- 

pan ies are increasingly dependent on 

their machine suppliers’ sound service 

infrastructure. One of the latest offerings 

of SCHLEIFRING SERVICE is, preventative 

maintenance. So-called care kits include the replacement or reconditioning of 

machine parts, depending on the machine running time. This guarantees availability 

and avoids future costs. 

� Things are happening 

Even if no one is able to predict exactly how the markets will develop during the 

next years, technological developments are emerging in several sectors which 

indicate that things are looking up. The energy sector, for example, has good future 

prospects as worldwide demand for electric energy is expected to rise in the long 

term. Demand for electricity in the industrial nations is consistently high. Emerging 

nations like the BRIC states (Brazil, Russia, India and China) are rapidly catching 

up. According to reports by the World Energy Council (WEC), worldwide demand 

for energy could rise 40 per cent by 2030 and could even double by 2050. The 

upgrading capacity required calls for new investments, as does the need for replacing 

old power stations which is imminent in particular in Europe and the US

in order to reduce emissions and in- 

crease effi ciency. The world-wide fund- 

ing of renewable energy, like wind or 

hydro power, cannot satisfy this huge 

additional demand on its own. 

Medical technology is also showing 

signs of growth. From therapy equip- 

ment and diagnostic equipment to the 

manufacture of new pharmaceuticals 

and packaging solutions which are in- 

dividually tailored according to con- 

sumption, of biocompatible prostheses 

like hip and knee joints – the range of 

products and services of the medical 

industry is developing at a rapid pace. 

The use of artifi cial knee and hip joints, 

for example, is constantly increasing. 

The main reasons for this are longer life 

expectancy and the associated increased 

wear of the joints, as well as implants 

at an increasingly younger age. 

Even the aircraft industry is subject to 

the current market turbulence. However, 

due to the long-term nature of the 

business, this sector has not been affected 

as much as the automotive industry. 

This is supported by current 

fl eet developments and passenger vol- 

umes. According to forecasts by the 

International Civil Aviation Organization 

(ICAO), passenger numbers could ex- 

ceed the 2008 levels as early as 2012. 

Stricter legal requirements for pollutant 

emissions and engine noise behavior 

and fi rm enquiries from the military sector will further fuel the demand for capital 

goods in this particular sector. 

The automotive industry and its suppliers were particularly hard hit by the crisis. 

Yet this sector will remain the most important market for the machine tool industry 

in the future. Experts estimate that by 2011, worldwide car production will have 

reached the same levels as 2008, but with different regional emphasis than today. 

The backlog demand in the emerging markets will also contribute to the increase 

in car sales. Alternative drive systems like hybrid or electric motors will be slow to 

establish themselves. Various studies are predicting that the share of electric motors 

for example, will barely exceed ten per cent and hybrids will not exceed 15 per 

cent by 2020. Global investment in the production of modern combustion engines 

will carry on as before. Legal requirements for the reduction of toxic emissions 

and the development of technologies that reduce fuel consumption require stateof-the-art 

production plants. 

� Windmills instead of walls 

Gigantic machines with a future: The demand for energy turbines is undiminished 

Artifi cial hip joint: The range of products and services of the medical industry is rapidly developing 

In these turbulent times, the SCHLEIFRING Group serves its customers as a reliable 

partner and is optimistic about the future. Optimism in particular, is an important 

aspect of crisis management, which is also confi 

rmed by the ‘growth study’ by Simon-Kucher 

& Partners. ‘It is important not to underestimate 

the psychological aspect,’ states Dr Philip Grote, 

author of the study. 2,600 European industrial 

enterprises took part in the survey. The result 

showed that four out of fi ve respondents rely on 

strengthening their innovative capability. Companies 

are not as badly affected by the crisis as 

commonly thought. It also states that the vast 

majority of businesses thinks and acts long-term. 

The most important goals are better service and 

customer proximity, innovative success and 

technological leadership. According to a Chinese 

proverb, ‘when winds blow, the strong build 

windmills, not walls. Or putting it a different way: 

it depends on what you make of it. 


11


EMO 2009 

Machinery. Fashion. Milan. 

Powerful machinery, effi cient software – the SCHLEIFRING Group at the EMO 2009. 

From October 5 to 10, 2009 the 

North Italian fashion metropolis 

of Milan is firmly in the grip of the 

TOOL GRINDING 

EWAG COMPACT LINE 

Compact and ergonomical 

At the EMO, EWAG is displaying the new COMPACT LINE. 

The fl exible and highly-accurate grinding machine was 

displayed for the fi rst time at the SCHLEIFRING Grinding 

Symposium 2009. With its compact design, ergonomic 

operation and its integrated robot system, the COMPACT 

LINE sets benchmarks in the smallest spaces – regardless 

of whether manufacturing or regrinding of indexable inserts 

in all materials. With the new PCD/PCBN module for 

grinding super-hard materials, the machine 

is now also equipped for r 

processing diamond 

cutting materials. 

EWAG demonstrates 

in Milan just how successfully 

the machine 

is working. 

For super-hard materials: 

The new COMPACT LINE 

by EWAG 


WALTER HELITRONIC POWER 

Bestseller r 

The world’s biggest- 

selling CNC toolgrinding 

machine 

just has to be on 

show at the biggest 

machine-tool trade e 

fair in the world. The he 

HELITRONIC POWER ER 

grinds rotationally symymmetric precision tools s for metaland 

woodworking, special tools 

and production parts of complex geometries. 

In its DIAMOND version, it 

Milan cathedral: The 

symbol of the trade fair city 

in Northern Italy 

machine tools industry. At this leading trade fair of the industry, KÖRBER 

SCHLEIFRING presents the latest developments in machinery concepts and 

controls. MOTION gives a run-down of the innovations. www.schleifring.net 

WALTER HELITRONIC 

POWER: The Biggestselling 

CNC machine 

sets the standard in surface quality, cutting edge quality and 

fl exibility. The 2-in-1 concept reacts fl exibly to all production 

demands. It can be switched over automatically from ERM 

to grinding, from processing PCD tools to production or 

regrinding of hard-metal tools. A wide range of optional 

loaders, measuring systems and grinding wheel changers 

increases fl exibility and productivity.

Short loading loadin times: The tiniest 

components are ar a specialty of the 

HELITRONIC MICR MICRO 

WALTER HELITRONIC MICRO 

Maximum precision and 

fl exibility 

Components in electronic and medical engineering are getting 

smaller all the time, and they demand the highest levels 

of precision and fl exibility in their manufacture. With six 

CNC-controlled grinding axes and a wheelhead with three 

grinding spindles, the HELITRONIC MICRO delivers the most 

precise grinding performance for micro-tools with diameters 

between 0.5 and 10 millimeters. All axes are fi tted with linear 

or torque motors as well as high-resolution direct measuring 

systems. A hydraulically operated shaft steady-rest 

guides long and very thin workpieces with a rotational accuracy 

of one micrometer. An integrated robot loader reduces 

loading times to an absolute minimum. 

CYLINDRICAL GRINDING 

STUDER S22 

Individually specifi ed 

STUDER presents the new all-round talent S22 at the 

EMO. With this universal cylindrical grinder the customer 

selects from a modular system exactly those machine 

components he really needs for his own application. 

The choice includes des 

all the components s 

which STUDER 

has ever developed, 

from 

workpiece headstocks 

in chuck 

or universal design n 

through standard rd 

or high-accuracy Caxes 

and various us 

performance stages ges 

of belt or motorized 

wheelhead to tail- 

All-round talent: The 

STUDER S22 can be customized 

stocks for standard, synchronous or extra-fi ne grinding 

applications. Diverse possibilities for dressing and other 

accessories like in-process gauging and clamping devices 

as well as sophisticated grinding software round off the 

extensive range. 

WALTER HELICHECK PRO/PLUS 

Unbeatable accuracy 

With sensitive materials and the smallest dimensions, such 

as can be ground on the HELITRONIC MICRO, optical 

non-contact measuring technology plays a decisive role. 

With the cutting edge rounding sensor (SKV), WALTER 

developed a non-contact method for exact measurement 

of face- and contour-rounding of cutting tools in the 

micrometer range. A CNC-controlled precision swivel axis 

with a swivel angle range from 0 to 90 degrees and a 

position resolution of 0.001 degrees and a × 1,000 precision 

optic measure the cutting geometries. The system, 

working on the aauto 

focus principle, is 

suitable suita for edge rounding of 

between betw three and fi fty micrometers. 

cro It is available 

as an option for the 

HELICHECK PRO/PLUS 

measuring machines. 

Non-contact: Non-c Precise 

measurement measu with the 

HELICHECK HELIC PRO/PLUS 

STUDER CT960 

For universal application 

With the CT960, STUDER is also showing a machine from 

the new subsidiary COMBITEC. The internal, universal 

and radius-grinding machine CT960 is a highly-accurate 

machine with a B-axis swiveling to 91°. A revolver with 

up to four spindles guarantees economy in grinding small 

to medium-sized workpieces. The CT960 is suitable for 

general grinding work just as well as for grinding complex 

workpieces of hard and brittle materials. The optimal 

stability and rigidity of the machine permits the grinding 

of dies with radii, cones or track contour. The fi nished 

workpieces have polished surface quality. In addition, 

STUDER 

presents the 

optional CNCcontrolled 

C-axis as well 

as the Sim-CT 

software. 

CT960: Suitable for grinding small 

to medium-sized workpieces 


13


STUDER CT450L 

Entry-level model 

The CT450L is an inexpensive yet powerful internal and universal 

grinding machine for simple grinding tasks such as 

drilling, plane surfaces and tapers and can also machine 

complex contours. The compact machine has a linear arrangement 

of spindles with up to two belt-driven spindles. 

It is also suitable for grinding extra-hard 

materials. materia Its particular advantages are 

above all the good accessibility for 

setting up, changing parts and 

measuring tasks and its low maintenance 

costs. 

STUDER SOFTWARE 

Halved machining times 


STUDER S33 

Classic in a 

new design 

The StuderTechnology intelligent software module is simply unbeatable, particularly for 

small and medium production runs: together with the basic StuderGRIND grinding software, 

the module itself calculates the process parameters for the respective grinding task 

on the basis of a technological database. All the operator has to do is enter the material, 

grinding wheel specifi cation, type of dressing tool and some other factors. By simply 

pressing a button he can then call up the system’s suggestions as to feed-rate, switching 

points, dressing amounts and spark-out time. Time-wasting adjustment is dispensed 

with and machine set-up times and machining times are appreciably reduced. 

New: The KRONOS 

S250 produces 

precision parts from 

1.5 mm diameter 

Simple or complicated: 

The CT450L is extremely 

versatile 

MIKROSA KRONOS S250 

Centerless multi-talent 

Altogether new is the KRONOS S250 centerless external 

cylindrical grinder by MIKROSA. Thanks to a maximum 

grinding wheel thickness of 250 millimeters, the machine 

can grind small, thin precision parts from 1.5 millimeters 

diameter and workpieces of up to 245 millimeters in length. 

Depending on the length of workpiece, a number of workpieces 

can be ground at the same time in the wide grinding 

gap. The multi-talent is similarly suitable for offset grinding 

wheels, guiding workpieces through the grinding gap and 

oscillation and angular plunge-cut grinding. 

conceals a host of new features 

Also to be seen at the EMO is 

the updated sales success STUDER S33 with all its new features. 

As suggested by many customers, the external and 

internal cylindrical grinding machine has been equipped with 

an additional, second external grinding wheel. Also new are 

the PC controls with StuderWIN software and the STUDER 

PCU2 manual operating unit. This increases the possibilities 

for application and its user-friendliness appreciably. Further 

proven STUDER features are the smartLoad with double gripper, 

the integrated measuring control with Movomatic digital 

measuring heads and incorporation of the engineering computer 

into StuderWIN and set-up in the 3-D machine room. 

SCHAUDT ShaftGrind S 

Simply convincing 

SCHAUDT is exhibiting the latest features of the ShaftGrind 

S with swivel-in spindle technology. The machine concept 

is ideal for the grinding of drive shafts and camshafts with 

a length of up to 650 millimeters. With the WOP-S programming 

ShaftGrind S generates noncircular surface contours 

quickly and easily, as well as free profi les. It is outstandingly 

suited for peel grinding processes as well as groove 

grinding using CBN. The swivel-in spindle makes it possible 

to grind with a range of different wheel thicknesses and is 

used to produce free ree and 

plunge cuts in intererpolation mode with h 

a galvanicallybonded 

grinding 

wheel. 

ShaftGrind S: Predestined 

for drive shafts and 

camshafts 

STUDER STUDERS33:Theoldname 

S33: The old name 

Time saver: STUDER software determines the 

process parameters for the grinding task

CNC CONTROLS DRIVE SYSTEMS LASER SYSTEMS SERVICE 

10 Years Production 

0 Failures 

100 % Availability 

Maximum machine availability: 

with CNCs from FANUC 

Our CNCs are the most reliable controls in the world: 

because statistics have demonstrated that the fi rst failure 

may not happen till 10 years have passed. This will save 

expensive services and reduce the TCO (Total Cost of 

Ownership) to a minimum. Your benefi t: highest reliability 

for maximum availability. 

Just one of our strengths. 

Fanuc GE CNC UK Ltd. / 15 Basset Court - Loake Close 

Grange Park / UK-Northampton NN4 5EZ 

Tel.: (+44) 1604 7441 30 / Fax: (+44) 1604 7441 31 

info.uk@fanucge.com / www.fanucge.co.uk 

Fanuc GE CNC Europe S.A. 

Zone Industrielle / L-6468 Echternach 

Tel.: (+352) 72 79 79 1 / Fax: (+352) 72 79 79 510 

info@fanucge.com / www.fanucge.com


MANUFACTURING QUALITY 

All according to plan 

planlauf GmbH, a machine 

dynamics expert is making a 

name for itself with vibration 

phenomena. 

More and more companies are relying 

on planlauf GmbH when it 

comes to machine analyses and evaluation. 

They provide expert support with 

root cause analysis and the elimination 

of vibration and precision problems on 

plant and machinery. In an interview 

with MOTION, managing director Dr 

Severin Hannig explains how manufacturing 

quality can be improved. On account 

of his innovative business ideas, 

the graduate of the WZL (Laboratory for 

Machine Tools, University of Aachen), 

has won this year’s Fritz Studer Award 

(see page 6). 

Dr Hannig, with regard to machine dynamics, 

what are the crucial factors 

when grinding workpieces? 

A decisive factor for a stable grinding 

process is the perfect alignment of the 

rigidity and damping characteristics between 

the basic machine, the tool, the 

clamping devices and the workpiece. 

To what extent does grinding determine 

the quality of the fi nished product? 

As a fi nishing process, grinding is at the 

end of the value added chain. Surface 

waviness or facets as a result of process 

vibration are unacceptable. The causes 

of these phenomena are complex and 

require extensive diagnostic procedures 

and a high degree of expertise as well 

as experience. 


Precise: Correct alignment between workpiece and machine achieves perfect results 

What advantage does the combined use of patented measuring technology and 

proven simulation and calculation procedures bring to the machine analysis? 

State-of-the-art sensor technology and standardized measuring strategy permit 

fast analysis of process vibration and precise detection of rigidity, structural resonance 

and vibration characteristics at the manufacturer’s or the user’s site. After 

‘It goes without saying that measuring 

the static and dynamic machine 

rigidity is normal practice for machine 

acceptance’ 

Dr Severin Hannig, Managing Director of planlauf GmbH 

systematic archiving, the results provide the basic concepts for the improvement 

of the dynamic characteristics of machines, tools and clamping devices. The advantages 

of high defi nition and the accuracy of metrological procedures can be 

further extended by calculation methods such as the fi nite element method (FEM) 

and the multi-body simulation method (MBS). While the accuracy of the simulation 

models is ensured through calibration with the measurements, the potential

for improvement or the risk of planned 

structural changes to machine structure, 

tools or clamping devices can be as- 

sessed during the concept stage and an 

effective choice can be made. 

What is a typical problem case? 

One example is visible and/or measu- 

rable grinding waviness with amplitudes 

of substantially below one micrometer 

in places. This can be caused by bearing 

damage, imbalance, dynamic radial de- 

viation of the spindles or incorrect set- 

tings. Other possibilities are external 

vibrations through fl oors and founda- 

tions caused by adjacent machines or 

nearby forklift traffi c, roads or railways 

and also by overshoot of the machine 

during quick axis movements. In the 

most common and most complex prob- 

lem cases, the vibrations are caused by 

the process forces themselves and are 

maintained or even intensifi ed through 

resonance points in fl exible machine 

structures or devices. 

What effect does the installation of 

superfi nishing machines have on the 

manufacturing quality? 

It has a huge effect. That is why we ex- 

amine foundations and fl oor slabs of 

production facilities for their suitability 

as a location for production machines 

and advise users on the installation of 

their machine. In the end, however, it is 

the static and dynamic rigidity properties 

of machine structure, tools, clamping 

devices and the workpiece itself 

which determine to what extent the positioning 

accuracy of the machine axes 

achievable in an unloaded state can be 

transferred to the machining accuracy 

under process load. 

Does high rigidity of the basic machine 

lead to a dynamically stable grinding 

process? 

No. Process stability is determined by 

all the components in the power fl ow. 

Machines with high rigidity in particular 

are prone to vibration because the de- 

vices and tools, which physically speak- 

Diagnosis: Dynamic 

machine characteristics 

should be observed to avoid 

vibrations when grinding 

ing have only limited damping, do not experience suffi cient damping through the 

machine structure. Evaluating resonance characteristics and the prognosis of 

possible effects on the manufacturing quality require experience which planlauf 

has built up by focusing specifi cally on the area of dynamics. 

What is the purpose of a machine analysis? 

Firstly, the separation into geometric, kinematic, thermal, static and dynamic 

causes which add up to a total error on the workpiece. Secondly, it is vital to 

identify the components responsible. Based on this, it is possible to derive calculated 

suggestions for improving the interaction between machine and process. 

Apart from structural changes to individual components, a targeted replacement 

of damaged components or changes to the workpiece clamping device can be 

carried out. We also offer the design and adjustment of additional damping systems 

such as auxiliary mass dampers. In certain cases, they are a quick and costeffective 

measure for increasing dynamic 

process stability. 

When do process vibrations occur? 

Process vibrations occur suddenly, for 

instance after alterations to the clamping 

devices, tools or workpieces. Irrespective 

of the production site, machine downtime 

leads to high costs. Therefore, our measuring 

equipment and diagnostic tools 

are designed for use all over the world 

and at short notice, if need be on the day 

after the problem occurs ensuring minimum 

time loss for your machine. 

planlauf GmbH 

planlauf GmbH was founded in 2007 

and is located right next to the 

Laboratory for Machine Tools (WZL) of 

the RWTH Aachen University. planlauf 

supports international manufacturing 

companies in the design, construction, 

assembly and operation of production 

machines, specializing in root cause 

analysis and elimination of dynamic 

vibration phenomena. 

www.planlauf.com 


17


SUPPLY INDUSTRY 

World class for market leader 

The building is in an idyllic setting. 

To the left is a lush meadow and on 

the horizon imposing alpine peaks. Yet 

the impression is deceptive, for the 

large sliding door conceals the manufacturing 

heart of Kostwein Maschinenbau 

GmbH. The family-run company, 

on the edge of Klagenfurt in the Austrian 

province of Carinthia, is one of the 

leading component suppliers in Europe. 

‘Here, we make everything, single parts, 

series production and even complete 

machines,’ says Wolfgang Kohlenbrein, 

head of production. ‘Our most important 

customers come from the packag- 


Well-packaged: 

Kostwein builds complete 

packaging machines 

Clean energy: Components 

for wind farms are 

manufactured at Kostwein 

Kostwein Maschinenbau GmbH promises enhanced performance with greatly reduced 

process times. SCHAUDT technology is helping the company to achieve this. 

ing, pharmaceutical and paper industries and the machine tools and environmen- 

tal technology sectors.’ Kostwein’s output includes complete packaging and 

printing machines and other important machine components. 

� Competent and reliable 

A good impression: 

Kostwein gives printing 

rolls the fi nal polish 

Kostwein aims to be the best supplier in Europe by 2011. ‘The supplier that can 

maintain its market position in the long-term is the one with a reputation for fast 

response to inquiries, the largest range of products and services, the shortest 

throughput times, the most innovative portfolio of technology and delivery on 

time. Our claim is that we produce world-class goods for market leaders,’ says 

CEO Hans Kostwein. For this reason, investment is the name of the game. In the 

last two years alone, the company has spent ten million euro. ‘With 250 CNC 

[1] [2] [3] 

Production at Kostwein: [1] Hans Kostwein, Sigurd Wulz, Ulla Kostwein and Erich Stolz (left to right) during a discussion [2] Sigurd Wulz clamping a printing cylinder 

[3] Small components for big brands – technology from Kostwein is included in many well-known products

machines at present, our production 

range is as broad as we can make it,’ 

says Kostwein. 

� Technology leaders 

For grinding, the Austrian company 

relies on SCHAUDT. ‘SCHLEIFRING 

Group machines are always at the forefront 

of technology and their reliability 

is excellent. This gives customers like 

Kostwein security in planning,’ says 

Erich Stolz of Metzler, the general agency 

representing SCHLEIFRING in Austria 

(see box). First of all, Kostwein 

purchased a FlexGrind M2000 UIB, 

which they use to make printing cylin- 

‘The SCHAUDT 

machines are the 

technology leaders 

in many aspects’ 

Sigurd Wulz, production 

manager at Kostwein 

ders, parts for packaging machines, 

elements for wind farms and other 

items. ‘The SCHAUDT machines are 

simply the technology leaders in many 

aspects,’ says Sigurd Wulz, production 

manager at Kostwein. ‘Innovative components 

such as the Diatronic measuring 

system developed by SCHAUDT 

streamline work processes. This helps 

us to considerably reduce lead times 

as required by our customers.’ 

� The zero-error principle 

The core of the measuring system is 

measurement in parallel with cutting 

time. This is done by connecting the machine 

to the Diatronic digital measuring 

head, thus achieving a high degree of 

precision. The quality of the component 

produced refl ects this. Programming is 

easy. Simply select the ‘grind with measuring 

head’ cycle and enter the relative 

position of the measuring head with respect 

to the grinding wheel. Programming 

is then complete and there is no 

The SCHAUDT Diatronic measuring system streamlines work processes and reduces throughput times 

need for any mechanical set-up procedures. ‘We work according to the zero-error 

principle here. I can rely on SCHAUDT and am sure that my components are always 

in perfect condition when they leave the machine,’ says Wulz. ‘If I were not grind- 

ing with measurement control I would need to stop at least twice per cycle to check.’ 

The Diatronic measuring system therefore creates process reliability and increases 

effi ciency. Operators can work with two or even more machines in parallel. In 

addition, Kostwein has converted its production to synchronous cycle production, 

i.e. the repetition of identical or virtually identical operations within defi ned timespans. 

‘This alone has enabled us to triple our output,’ says Wulz. He quotes the 

manufacture of packaging machines as 

an example. ‘Instead of two as before, FURTHER INFORMATION 

we can now produce six complete ma- +++ irina.hafner@schaudt.com +++ 

chines within a week – that’s six per www.schaudt.com +++ 

production line.’ 

www.kostwein.at +++ 

KÖRBER SCHLEIFRING IN AUSTRIA 

General agency Metzler GmbH & Co. KG 

Customers in Austria, like Kostwein Maschinenbau GmbH, are looked after by 

Metzler GmbH & Co. KG, the general agent for the SCHLEIFRING Group in the alpine 

republic. Metzler has more than 20 years’ accumulated expertise in the area of 

technical commerce and is one of the most important companies in the country. ‘We 

provide guidance for the approximately 2,500 customers that we have, showing them 

the right procurement process for tools and machines,’ says CEO Reinhard Metzler. 

The company works shoulder-to-shoulder with the international sales and service 

subsidiaries of the SCHLEIFRING Group. www.metzler.at 


19


ELECTRIC MOTOR PRODUCTION 

A quantum leap 

Machine manufacturer 

Otto Suhner replaces six 

conventional machines with 

the STUDER S242 – and 

achieves up to 70 per cent 

more productivity. 

The Swiss fi rm Otto Suhner GmbH 

specializes in the small batch production 

of drive components. At its Ger- 

man site in Bad Säckingen, the experts 

produce electric motors for hand tools 

such as angle grinders and plaster saws 

or thread cutters and presses. Their 

customers mainly come from the skilled 

trades but also increasingly from medical 

technology and the sanitary sector. 

‘We offer standardized drive and power 

transmission elements for new developments 

in machines and tools, originating 

from our current production of electric 

hand tools for abrasive surface 

machining,’ explains Gerhard Schmid, 

Head of Production. Suhner products 

are particularly sought-after in Germany. 

Here, the market for electric motors 

is generally stable. 

� Complete machining 

in one clamping 

Previously Suhner used six individual 

steps, each on a different conventional 

machine, to produce the armatures for 

its electric motors (see right): fi rst, the 

thread was turned, then the collector 

and core assembly and lastly the four 

different diameters of the armatures 


were ground. For each diameter, Suhner used a different machine. This made 

heavy demands on time, transport, space and personnel. Now a single adaptable 

hard fi ne machining center replaces these six machines. The STUDER S242 

now machines the armatures for the electric motors without any need for re- 

clamping. ‘The machine met our expectations right from the start. We are not 

only saving time and money; the improved concentricity of all the batches makes 

our motors quieter and more durable. We are more than satisfi ed,’ says Schmid. 

‘Our fast-running shafts and armatures require extremely tight concentricity 

tolerances and these can only be achieved by clamping the component just once. 

These days, we are making about 10,000 armatures a month. They are clamped 

between centers and driven synchronously with the main spindle and counterspindle. 

The STUDER 

easyLoad XL loading 

system automatically 

loads and unloads 

the machine.’ 

Since the S242 has 

been operating at 

Suhner, the material 

fl ow has become 

considerably simpler 

and process times 

have improved mark- 

Angle grinders: 

The STUDER S242 ensures 

more accurate concentricity 

S242: THE ADVANTAGES AT A GLANCE 

Combined machining; hard turning and grinding in one 

clamping 

Reduction and sustainable optimization of structural 

costs. 

High reproducible positional accuracy and concentricity 

Low process and auxiliary times. 

Preprocessing close to fi nal contours 

Surface structures appropriate to function 

Customer-specifi c placement of cross slides 

Up to 70 per cent increase in productivity

[1] [2] 

Small-scale muscle: [1] Suhner belt sanding machines are used to grind and polish pipes in property construction [2] The improved concentricity of armature shafts 

makes electric motors quieter and extends their service life 

SIX PROCESSES ON ONE MACHINE 

Machine 1 

Thread turning 

Machine 4 

Previously, six machines were used at Otto Suhner GmbH to produce armature shafts for electric motors. This meant six times 

the labor costs plus transport and idle times. Now the STUDER S242 combines all the working steps with the workpiece clamped 

just once. The result: lower labor costs, no transport or idle times and, at the same time, greater accuracy. 

edly. Up to 70 per cent increases in 

productivity are realistic. 

� A clever combination 

Machine 2 

Turning collectors and laminated cores 

Machine 5 

Suhner profi ts from the sophisticated 

concept of the S242: The grinding head 

and tool revolver are parallel to each 

other. The modular construction of the 

hard fi ne machining center, combined 

with two (short version) or three cross 

slides (long version) offers an unimaginable 

range of possible confi gurations 

for external and internal grinding and/ 

or hard turning plus hard reaming, mill- 

ing and drilling. With two slides, as used 

at Suhner, the S242 reaches center dis- 

tances of 400 and 1,000 millimeters. A third cross slide extends the range by 

center distances of 800 millimeters. Reconfi guring the extremely versatile S242 

is quickly done, making it eminently suitable for the contract manufacturing of 

single components as well as for small and large batch production. 

� Expansion and new jobs 

By deciding to purchase the S242, Suhner has confi rmed the strong trend in the 

sector towards complete machining. Thanks to the new machine, this tradi- 

tional Swiss company can produce higher-quality armatures without idle times 

and transport costs. The machine only needs one person to operate it. ‘The increase 

in production and the cost benefi t that the S242 has brought us was so 

enormous that we are expanding and can create new jobs for our operators on 

the other fi ve machines,’ says Gerhard Schmid. 

And he has taken a large step towards his aim FURTHER INFORMATION 

of achieving 15 per cent growth in electric 

motor production. 

Machine 3 

Grinding Ø 7 

Grinding Ø 8 Grinding Ø 9 

Grinding Ø 10 

Machine Mac Machin hin hi hin hine e e6 e e6 e e6 e e6 e e6 e e6 e e6 6 

STUDER S242 

+++ michele.fahrni@studer. 

com +++ www.studer.com +++ 


21


HISTORY 

Determined: Kurt A. 

Körber always 

knew the way 

forward 

Advancing society and initiating thoughtprovoking 

discussions played an important 

part in the life of Kurt A. Körber. 


THE T FOUNDER OF THE KÖRBER GROUP 

Inventor, entrepreneur, founder and instigator 

Never start stopping, never stop 

starting – Kurt A. Körber lived and 

acted by this motto throughout his life. 

The honorary citizen of Hamburg and 

founder of the Körber Group would have 

been 100 this year. 

Born in Berlin, on 7 September 1909, he 

grew up in modest circumstances. His 

father Paul Körber was a technician who 

favored an authoritarian style of parenting 

and followed the traditional role 

pattern. His mother, Lina Auguste Rosa 

Nickol, however, was not infl uenced by 

this and became politically active. 

She supported Rosa Luxemburg and 

Young professional: Körber as a young engineer in his offi ce at Siemens 

often took her son Kurt along to political meetings. These experiences helped to 

shape his social consciousness as early as his teens. Kurt A. Körber’s practical 

genius was discovered and nurtured by his father. Aged 14, Kurt applied for the 

so-called Audion test permit which would allow him to experiment with radio 

receivers. He made his fi rst invention when he was 15 and applied for a patent 

forthwith: an automatically controlled transmitter-reader scale. Since the radios 

equipped with his scale sold so well, Körber was able to fi nance his studies with 

the proceeds. 

� Right time, right place 

Körber’s professional career started with an electrical apprenticeship which was 

followed by electrical engineering studies. Following this, he started working for

Siemens. The fact that he did not stay 

there long was down to chance. The 

Universelle-Werke in Dresden required 

a machine that would place cigarettes 

into the packet in a way that would show 

the writing on the cigarettes on opening 

the packet. They made inquiries with 

Siemens about this project. As Körber 

had just developed a color controlling 

device for automatic sorting equipment, 

he not only became the technician in 

charge of the joint project, but was also 

headhunted by Universelle once the collaboration 

had fi nished. Within the 

space of just nine years, Körber 

had worked his way up to 

become technical director. 

After the Second World War, 

Kurt A. Körber quickly realized 

that Northern Germany was to 

become the center of the German 

tobacco industry and that 

his time in Dresden had come 

to an end. He therefore relocated 

to Hamburg in 1946 and 

set up the Hanseatische Universelle 

– Hauni for short – 

which is part of the Körber 

Group to this day. 

� Well-known around the world 

Contacts with cigarette manufacturer 

Philipp Reemtsma helped Körber, newly 

settled in Hamburg, to gain a foothold 

in the tobacco industry. Initially, Hauni 

had eight employees repairing used 

cigarette machines. The company then 

had its fi rst success with an innovative 

hand-operated tobacco cutter. Körber 

secured worldwide market leadership 

with the development of a machine for 

attaching cigarette fi lters. At that time 

Hauni had just under 1,000 employees. 

When dealing with his employees, Körber 

paid particular attention to maintaining 

an air of discipline. He encouraged 

team spirit among his workforce by organizing 

regular company holidays. The 

welfare of his employees was dear to his 

heart. He appointed a company doctor 

and established a staff canteen and 

sports facilities on-site. 

Political circle: The Bergedorf Round Table visits Dresden 

Hands-on: Kurt A. Körber was not above 

carrying out repairs himself 

A FORUM FOR IMPULSES 

A short history of the Körber Foundation 

Successful project: Kurt A. Körber speaking 

at the 10th anniversary of the TTH 

The Kurt A. Körber Foundation was established in 1959. Körber later merged 

it with the Hauni Foundation to form the Körber Foundation. As Kurt A. Körber 

had no children, the foundation inherited his private fortune. 

The mission of the foundation can be found in its charter: ‘The 

immediate and exclusive purpose of the foundation is the creation and 

maintenance of an Academy for Industrial Working Methods.’ 

The Körber Foundation aims to help shape the future of society through 

its projects and collaborations. To this end, it organizes Political Breakfasts, 

offers the Körber networks for history didactics and foreign politics, and 

champions cultural education. 

The foundation awards prizes in areas like international politics, 

education, science, society and young culture and stimulates 

discussion. In addition, the KörberForum offers a place for people who 

are not prepared to leave things as they are. 

The Körber Foundation is the sole shareholder of Körber AG. 

www.koerber-stiftung.de 


23


Sociable: Kurt Körber with Loki and Helmut Schmidt 

and Rolf Liebermann attending an opera ball 

Through strong international contacts 

Kurt A. Körber ensured Hauni’s worldwide 

growth. 

In the late 1960s, Körber ventured into 

unknown economic terrain for the fi rst 

time ever by taking over a company in the 

paper sector. In 1978, the foundation for 

KÖRBER SCHLEIFRING was laid when 

former Chancellor Helmut Schmidt ap- 

proached the entrepreneur with a request. 

He asked Körber to take over the Bergedorf 

grinding machine manufacturer Blohm in 

order to save them from bankruptcy. The 

next election was imminent and BLOHM 

was in Schmidt’s electoral district. 


The private person: Kurt A. Körber at his 

villa in Bergedorf with his mother Rosa 

(center) and his wife Anna-Katharina 

Körber examined the situation and was convinced that the takeover would fi t in 

well with his entrepreneurial interests. He was proved right and thanks to his courage, 

the SCHLEIFRING Group was able to become what it is today. 

� Encourage and challenge 

Kurt A. Körber was not satisfi ed with simply devoting himself to his company. 

His main objective was to be the catalyst for new developments. On his 50th 

birthday, Körber created the framework for promoting education by establishing 

the Kurt A. Körber Foundation (see box on page 23). In 1956, he set up the Tabak 

Technikum Hamburg (TTH), launched the bio engineering degree course and 

started the Cultural Relation Fellowship (CRF) exchange program in 1980. In addition, 

Körber was instrumental in creating the Federal President’s historical 

competition and sponsored prizes like the Boy Gobert Prize for up-and-coming 

young actors and the Körber Prize for European science which is awarded annually 

at Hamburg’s city hall. 

The Bergedorf Round Table, a series of conferences which have been taking place 

regularly since 1961, has achieved international importance. Körber considered 

these meetings to be his best invention. They provide politicians, experts and 

scientists from all over the world with a forum for dialogue away from the public 

eye. Even today, 17 years after Körber’s death, the Bergedorf Round Table continues 

to meet three times a year.

Gauging and 

control for 

grinding machines 

Leading... 

...results from 

the perfect combination 

of many factors 

Acoustic 

sensors for 

grinders 

Grinding wheel 

balancing 

systems 

Please visit our website where you will find more detailed information and your nearest Marposs office. 

www.marposs.com www.marposs.de www.marposs.ch 

If your targets are: 

To encrease productivity, 

To reduce production costs, 

Then contact us!


MEDICAL TECHNOLOGY 

Partner to pharmaceutical sector 

The medical industry is experiencing a period of rapid and continuous transformation. Packaging 

systems manufacturer Uhlmann, a partner to the sector, is keeping pace with the rapid changes. 

BLOHM JUNG is supplying the necessary technology with its PLANOMAT grinding machine. 

Markus Haid is extremely well 

versed when it comes to pharmaceutical 

packaging. He is the managing 

director of Uhlmann Packaging Systems 

LP, an original equipment manufacturer 

of packaging systems for the pharmaceutical 

industry. The company, with its 

headquarters in Towaco, New Jersey, 

serves a sector which is subject to daily 

changes. While patents for highly 

profi table drugs are expiring, competition 

from cheap generic products is on 

the increase. Seen against this background, 

pharmaceutical manufacturers 

have to become leaner and more intelligent. 

They need the support of strategic 

partners for this. 

� Better management 

of medicines 

The pharmaceutical market is also affected 

by changes in the dispensing of 

drugs. So-called blister packs, for example, 

can help patients to manage 

their medicines more effectively. 


� The heart of a packaging machine 

Hygienic and 

functional: Blister 

packs also display 

instructions on the 

packaging 

Embossing tools are the heart of a blister packaging machine. They are used to 

make the blisters and to cut and trim the packaging after the tablets have been 

inserted. The demands made on up-to-date embossing tools are high. Often a 

knurled pattern has to be ground into the surface of the embossing tool. Previously, 

the production of this pattern took up to eight hours. Uhlmann required a 

reliable partner offering expertise and machines to support the grinding processes. 

Haid decided on the BLOHM PLANOMAT HP. High-precision re-circulating 

ball screws with digital drives permit high feed rates and accelerations compared 

to conventional machines. 

With the help of the BLOHM PLANOMAT, Uhlmann employees Bill Oehler and 

Keith Colville are able to reduce the grinding process to just 45 minutes. This 

represents an improvement of more than 1,000 per cent,’ says Colville. Uhlmann 

packaging systems use CBN grinding machines for pre-grinding the blanks. I use 

a custom-made tool to put the knurled pattern into the blank.’ A BLOHM profi le 

software package transforms the CAD form data quickly into grinding wheel 

profi les (CAD data). The BLOHM profi le software allows employees to import 

the fi le from the design server. We then select the required characteristics for 

the grinding wheel shape. An online simulation ensures that the desired shape 

is correctly produced by the selected diamond tools. As soon as the simulation 

has fi nished, BLOHM profi le automatically creates the necessary dressing program 

in the required syntax,’ explains Bill Oehler. Due to the high demands on fl exi-

ility which are made by constant 

changes and new shapes, dressing 

takes place with universal diamond 

dressing discs. In many cases two laterally 

reversed diamond wheels are used, 

which enable the creation of any profi 

le,’ says Keith Colville. 

� Faster than 

traditional machines 

Once the shape of the wheel has been 

created, the main focus is on the devel- 

opment of a grinding program for the 

specifi c part. The optimum grinding 

technology is automatically determined. 

The ECO plunge grinding method is 

used for some fl at profi les. The Blohm 

PLANOMAT can reach table speeds of 

40 m/min, making it at least 33 per cent 

FURTHER INFORMATION 

+++ diethard.liesack@blohmjung. 

com +++ mhaid@uhlmann-usa.com 

+++ www.uhlmann.de +++ 

[1] 

[2] 

Manufacture of blister packs: [1] Installation of 

packaging plant [2] Servicing a machine 

faster than traditional machines. Other part confi gurations have a deeper profi le 

with a more complex form. This is where deep feed grinding is used. ’Thanks to 

the BLOHM JUNG technology, I can continue to offer my customers tailor-made 

fl exible solutions’, sums up Markus Haid – A service which pharmaceutical companies 

greatly appreciate.


ENERGY TURBINES 

MÄGERLE steps on the gas 

Sustainable energy: 

Gas turbines are effi cient 

and low-polluting 

The energy sector is looking towards a promising future with effi cient and eco-friendly 

gas turbines playing a decisive part. MÄGERLE grinding centers offer manufacturers 

important competitive advantages by increasing productivity. 

The global demand for energy is increasing. 

Experts estimate that 

power consumption in China alone will 

increase fi ve-fold between 2000 and 

2025. As a result, capacity in the en- 

ergy sector is constantly being developed 

all over the world. The power is 

often generated by gas turbines. 

The Siemens SGT5-8000H weighs 440 

tons and has a gross power output of 

340 megawatt; it is currently the largest 

of its kind in the world. Gas turbines 

reach their full output within a few minutes 

and are often used to satisfy peak 

demand for electricity. 


� Around the globe 

Companies like Siemens, General Electric and Mitsubishi are counting on strong 

partners like MÄGERLE for the production of these turbines. The grinding machine 

manufacturer supplies power plant manufacturers worldwide with its grinding 

centers. ‘Utmost reliability, faultless functionality and excellent service are the 

essential criteria that set us apart from the competition. The important ingredients 

of sustained success are not only technical characteristics but a mixture of different 

criteria,’ says Roland Rütti CEO of MÄGERLE. In the energy turbine sector, the 

most important components such as shafts and buckets are manufactured on 

MÄGERLE machines. In order to satisfy the global demand for more energy in the 

future, customers from the energy sector are having to continually increase their 

productivity. One method of achieving this goal is the reduction of unproductive

Source: DOE/EIA 

DETAILED VIEW: THE 

MÄGERLE MGC-L-330 

[1] 

Hydrostatic and 

hydraulic unit 

[2] Control unit 

[3] 

[4] 

[5] 

180° swiveling table 

console 

2-axis NC dividing 

device 

Rotating grinding 

wheel changer with 6 

positions 

Intelligent machine concept: The MÄGERLE MGC-L-330 can drastically reduce downtimes when machining turbine buckets. s. 

The swiveling 180 degree table plays an important part in this (circular photo) 

downtime. Here, the Swiss company of- 

fers up-to-date and fl exible solutions. 

The MÄGERLE MGC-L-330 witch manufactures 

turbine buckets is able to drastically 

reduce downtime due to its intelligent 

machine concept. In the energy 

turbine industry, medium to large buck- 

ELECTRICITY CONSUMPTION 

Billion kWh 

30,000 

25,000 

20,000 

15,000 

10,000 

5,000 

0 

1990 2000 2010 2015 2020 2025 

� Central and South 

America 

� Africa 

� Middle East 

� Emerging markets Asia 

� Eastern European transition 

countries 

� Asian industrial nations 

� Western Europe 

� North America 

[4] 

[1] [3] 

[2] 

ets are not always machined on fully automated machines. Exchanging the machined 

turbine bucket takes relatively long compared to the machining time. Not 

just the parts themselves have to be changed over the new part also has to be 

carefully placed in the right position. In the case of ordinary grinding centers the 

machine stops during workpiece change, resulting in long, unproductive times. 

The MÄGERLE machine concept reduces this non-productive time down to a 

minimum. The core element of this concept is the 180 degrees swivel table equipped 

with two NC combinations for holding workpieces. Whilst one piece 

is being machined, the fi nished piece can easily be exchanged for 

an unmachined piece. The inside and outside working areas are 

separated by a solid revolving wall, providing a safe and clean work- 

ing environment at the changeover point. The workpiece change 

can be automated as a future option. The time saved more than 

compensates for the fact that this concept requires two NC combinations 

and two clamping devices for different set-ups. 

� Unique changing system 

The integrated grinding wheel changer also plays a crucial part in 

the reduction of downtime. Large grinding wheels with a diameter 

of up to 550 mm and a width of 220 mm can be changed quickly and 

safely. This innovative system permits high fl exibility when breaking 

down and minimizing operation steps and the number of clampings 

required. The dressing devices have been designed for the CD method 

which is mainly used in the manufacture of turbine buckets. Allowing 

the customer utmost fl exibility when dressing with minimum 

tool expenditure. NC control- 

led water jets round off the 

machine concept and permit 

optimum coolant supply. 

[5] 


+++ roland.ruetti@maegerle.com 

+++ www.maegerle.com +++ 


29


TOOL- AND MOLD-MAKING 

Unbeatable accuracy 

Mold-makers Fischer GmbH 

and the Söhnergroup produce 

high-quality injection-molded 

plastic components. They 

construct their tools 

themselves – using JUNG 

profi le grinding machines. 

The core business for both family 

concerns, Fischer GmbH and the 

Söhnergroup, is injection-molded parts 

for the automotive industry. The recent 

fall-off in sales in the sector had its effect 

on both of these traditional operations. 

Admittedly, Werner Fischer, founder and 

[1] 

[2] 

Production at Fischer: [1] The mold-makers from 

Sinsheim manufacture absolutely free of burrs 

[2] Precision-ground metal-in plastic part 


Special area injection molding tools: To achieve parts totally free of burrs, the molds have to be totally tight 

chief executive of the Sinsheim mold-maker, sees light 

at the end of the tunnel. ‘The situation in the market 

has already recovered substantially,’ he says. ‘At 

the end of 2008, we were only working at 40 per 

Regulator unit 

cent of capacity, but in the meantime we are 

for automatic airconditioning 

at least back up to 75 per cent.’ 

Harald Kümmerle, manager, mold making 

at the Söhnergroup, is sure too: ‘At the mo- 

Engine and 

ment there is no room for investment in 

gearbox controls 

new machinery, but we’ll come out of the 

crisis stronger than we went in.’ Werner 

Fischer sees the foundations for this in 

strong specialization of the concern. 

� Flowing like water 

Among other things, he has consistently 

set his sights on the production of highly- 

accurate, absolutely burr-free plastic parts 

for the auto electrics and electronics sector 

and construction of appropriate injection 

molding tools. ‘When injected in the mold, 

the plastic is as runny as water. To produce 

parts totally without burrs, the molds have 

to be absolutely tight. For this, we have to 

Alternator and 

car lighting 

Brake servo, ESP 

control unit

grind the contact surfaces between 

matrices and punch to a tolerance of 

2 micrometers everywhere,’ as Helmut 

Fischer, toolmaking manager, g , explains. 

To be able to guarantee rantee 

this, Fischer constructs cts 

these special tools on a 

JUNG J 630 using a PA 

37 K profi le dresser 

with diamond wheel 

and a dressing radius 

of 0.15 millimeters. 

‘The machine transfers 

and dresses automatt- 

ically and is so reliable that 

we could let it run unmanned manned Production at Söhner: [1] For all profi le and contour grinding tasks, BLOHM JUNG machines are used 

all night,’ adds Werner Fischer. 

[2] Fine mechanical structures require sharp corners and a special quality surface fi nish 

� Cost-effi cient and fl exible 

‘The operator has a JUNG machine un- 

der control within a day,’ says Harald 

Kümmerle. His concern specializes in the 

manufacture of precision technical plas- 

tic parts and apart from its major con- 

centration on automotive, it is continu- 

ously extending its sanitary and 

household technology range. ‘In this sec- 

On-board computer, 

multi-function 

steering wheel 

Electric windowwinders 

Fuel gauge, 

mileage counter 

CD-changer and 

sound system 

Electronics in the automobile: Many components are 

installed in the vehicle using plastic connections. In 

the manufacture of such injection-molded parts, 

casting molds of the highest quality are required 

[1] 

tor, the technical design of the products, the particular quality of visible surfaces 

and the fi ne mechanical structure of the components play an immensely important 

role – and that within narrow geometric dimensioning and tolerancing,’ explains 

Kümmerle. This is why Söhner only ever uses JUNG machines for all profi le and 

contour grinding tasks and grinding guideways. Wherever we can grind, we grind. 

That is the only way to achieve the fi ne structures and sharp corners we need for 

our products,’ opines Carsten Bauer, manager, grinding shop at Söhner. His company 

even uses the machines for cylinder grinding. ‘We grind short runs of cylindrical 

parts with diameters up to 40 millimeters with the help of a centerless cylindrical 

grinder on a JUNG surface grinder,’ says Bauer. Through such methods, 

Söhner achieves the best possible cost effi ciency and fl exibility. ‘For each of the 

three JUNG machines a separate programmer station was set up and various 

software modifi cations were incorporated. This way Söhner realizes fl exible and 

very fast data transfer for programming the wheel contours.’ In addition, Söhner 

optimized the grinding process of the CNC machines by using the optional processparallel 

grinding wheel dressing. Bauer: ‘The continuous resharpening of the wheel 

during the grinding process makes an appreciably faster feed and thus a better 

rate of metal removal possible. Apart from that, we reduce the heat taken up by 

the piece being ground. This minimizes possible tensions in the workpieces.’ 

� Permanently μ-accurate 

‘No other machine is so precise, so easy to use or so quiet. Our fi rst JUNG HF 50, 

dating from 1972, we have just had fully overhauled. It looks as if we had bought it 

yesterday, and for tuning work, it is still one of the best machines in the factory,’ 

declares Werner Fischer, who uses a total of 15 JUNG machines in production. 

He praises above all the unique ergonomics and the simple program structure. Carsten 

Bauer highlights in particular the precision of the machines. ‘The dimensional ac- 

curacy of the JUNG machine is unbeatable. Over several hours, it is possible to achieve 

tolerance compliance of better than 0.003 mm.’ 

On top of that, he is impressed by the compact 

design and the extreme fl exibility of the ma- 

chines. ‘There was and is no alternative to 

JUNG,’ as the two grinder experts agree. 

[2] 

Groove width 0,16 mm 


+++ uwe.henning@blohmjung.com 

+++ www.fischerwzb.de +++ 

www.soehnergroup.com +++ 


31


NEWSLETTER 

Sheer brilliance! 

Practical: ‘upgrade’ gives 

information on well-thoughtout 

grinding applications 


upgrade 

01 

Göppingen 

Aufgabe: Verschleisskompensation Abrichtdiamanten 

PA37K 

Lösung: Geoid – Geometrie Identifikation 

Branche: Werkzeug- und Formenbau 

Steigende Anforderungen an die 

Konturgenauigkeit beim Profilabrichten 

waren der Au lö f 

The new ‘upgrade’ newsletter from JUNG shows how you can further improve effi ciency in 

precision and surface quality in manufacturing using innovative grinding applications. 

Faster, higher, further – the boundaries 

in modern production are continuously 

on the move. For companies, 

this means making optimum use of 

available resources. One of the basic 

requirements for staying competitive. 

BLOHM JUNG at their facility in 

Göppingen would like to make an important 

contribution to this. From now on, 

the company will be sending out the ‘upgrade’ 

newsletter every two months free 

of charge giving information on important 

developments. There will be practi- 

cal tips and hints too: starting with accessories for optimized processes, through 

well-thought-out grinding applications to concrete examples as to how productivity 

and quality can be even further improved. 

� Download or order 

So far, three issues of ‘upgrade’ have been published (see right), which you can 

download in the form of a PDF fi le. Or you can order ‘upgrade’ per e-mail without 

any obligation. 

Download under: 

www.blohmjung.com 

Order per e-mail to: info-gp@blohmjung.com 

08/09

[1] 

Perfect contours: GEOID 

in combination with 

fl exible dressing systems [1 + 2] guarantees the result 

on the grinding wheel 

Process reliability: The 

measuring sensor [1] checks ks 

the manual adjustment and d 

determines the starting 

position for grinding [2] 

Starting point & task: Increasing demands of contour ac- 

curacy in profi le dressing. Wear compensation of dressing 

diamonds on the PA 37 K dressing system. 

Solution: GEOID – Geometry identifi cation. Using a measuring 

sensor, the correction software determines the actual 

contour of the diamond and corrects the dressing 

program accordingly. 

upgrade 

01 


Göppingen 

Aufgabe: Verschleisskompensation Abrichtdiamanten 

PA37K 

Lösung: Geoid – Geometrie Identifikation 

Branche: Werkzeug- und Formenbau 

Steigende Anforderungen an die 

Konturgenauigkeit beim Profilabrichten 

waren der Auslöser für die Weiterentwicklung 

der automatischen Diamantjustage und 

somit die Geburtsstunde von GEOID. 

Die Topographie der Schneidkante am 

Abrichtwerkzeug wird durch einen 

automatischen Messtaster �m genau 

ermittelt, um eine perfekte Kontur auf der 

Schleifscheibe herzustellen. 

Konturen werden mit einzelnen 

Profildiamanten oder Diamanträdern mit 

definierten Schneidkanten an die 

Schleifscheibe profiliert. Gängige 

Schneidkanten besitzen einen definierten 

Schneidenradius in den Größen 0.125, 0.250, 

sowie 0.500 mm. Auch Sondergrößen, sind in 

davon abweichenden Schneidenradien 

verfügbar. 

08/09 

Da der Schneidenradius direkten Einfluss auf 

die Konturgenauigkeit hat, ist er mit 

äußerster Sorgfalt zu betrachten. 

Bereits neue Abrichtwerkzeuge können 

Abweichungen von wenigen �m haben. 

Zusätzliche Abweichungen entstehen durch 

Verschleiß während des Abrichtvorganges. 

Egal wie gering die Abweichungen sind, sie 

wirken sich direkt auf die Profilgeometrie an 

der Schleifscheibe und dadurch später am 

Werkstück aus. 

Advantages: Faults in the cutting edge geometry are recorded and compensated 

even at the tiniest deviations. The service life of individual dressing diamonds is 

increased by more than 50 per cent. At the same time, the tool costs are reduced 

by more than 50 per cent, as are the processing times and the reject rate. 

Branche: Werkzeug- und Formenbau. 

Starting point & task: Grinding gear profi les and free forms taking 

the example of the external contour of upper and lower punches. 

Processes used until now: EDM machining and HSC milling. 

Solution: JUNG C 740 D with indexing unit and exchangeable 

high-speed grinder. 

Advantages: 60 per cent less processing times and 50 per cent lower tool costs. At 

the same time, 20 per cent more accuracy and in addition a doubling of the service 

life of the sinter punch. 

Sector: Sinter compression molding dies / automotive. 

[1] 

[2] 

upgrade 01: Wear Compensation 

upgrade 02: Gear profi les and free forms 

[2] 

upgrade 03: Automated process controls 

Fast: Gear wheel manufacture on a JUNG C 740 D 

More effi ciency: Drastically falling costs 

Starting point & task: How can adjustment errors be recognized 

and avoided before the grinding operation? Improving process 

reliability. 

Solution: Automated process control with an extensible mea- 

suring sensor, optional for all JUNG grinding machines for 

highly-accurate workpiece measurements. 

Advantages: Quality assurance by increasing dimensional accuracy. 25 per cent 

time saved through eliminating intermediate manual measurement. Reducing the 

rejection rate to 0 per cent. 

Sector: Mechanical engineering. 

100 % 

80 

60 

40 

20 

0 

Workpiece costs 

-50 % 

EDM & HSC Grinding on a C 740 D 

33


FOCUS ON INDIA 

Asia’s up-and-coming subcontinent 

India is a nation of superlatives: 1.2 billion people live here on an area nine 

times the size of Germany. India’s economic performance is also impressive. 

The SCHLEIFRING Group has been in India for many years. 

After the 1991 fi nancial crisis, the 

Indian economy was gradually deregulated 

and liberalized. This set the 

scene for India’s economic ascent fol- 

lowing decades of slow growth. Today, 

the Indian economy boasts the world’s 

second highest growth rate after China. 

In the past four years, gross domestic 

product (GDP) has increased by between 

seven and nine per cent. Even in the current 

global economic climate, India’s 


Indian landmark: The 

Taj Mahal in Agra has 

been a UNESCO 

World Heritage Site 

since 1983 

economy is growing by 7.1 per cent, according to Germany’s Federal Foreign 

Offi ce. In terms of nominal GDP, India has the eleventh largest economy in the 

world. Industrial production is concentrated on a handful of urban conglomera- 

tions, like Mumbai-Pune, Delhi and Chennai-Bengaluru. Bengaluru (formerly 

Bangalore) has become established as a center for information- and machine tool 

technology, while Hyderabad is a focal point for biotechnology. India’s pharmaceutical 

industry is one of the largest and most advanced among the developing 

and emerging countries. 

[4]

[1] 

[3] [3] 

� Trade quadrupled 

The subcontinent is rich in mineral re- 

sources: Indian soil holds reserves of 

high-grade iron and manganese ore, 

anthracite, bauxite and chromium. The 

country is able to cover around a third 

of its oil and gas requirements with its 

own reserves. India is the world’s third 

[2] [2] 

India in color: [1] An elephant collects money during a procession [2] Production hall of Tata Motors, India’s 

largest car manufacturer [3] Rohit Pereira runs the India branch office of the SCHLEIFRING Group in Bengaluru 

[4] Pilgrims bathing in the Ganges 

largest producer of anthracite and the fourth largest producer of iron ore. Foreign 

trade has been characterized by high growth rates for years, more than tripling 

in dollar terms over the past fi ve years. Nevertheless, the Indian economy is still 

very heavily focused on the domestic market. In order to be able to continue to 

grow, India needs a large number of good-quality machines. Plant and machinery 

were among the top three imports in the 2007/08 fi nancial year, accounting for 

10.1 per cent of total imports. Machinery production increased by 10.4 per cent 

over the same period. 

� More than 1,000 machines in 30 years 

KÖRBER SCHLEIFRING has been established on the Indian market as a vendor of 

high-quality machines for three decades. The local SCHLEIFRING branch has sold 

over 1,000 machines in this time. The branch offi ce in Bengaluru deals with sales 

and customer service for the Indian market. This vast, booming metropolis in the 

south of the country has a lot to offer – and not just as a manufacturing location. 

The capital of the state of Karnataka has earned itself a number of different names: 

the ‘Garden City’, the ‘Silicon Valley of the East’ and the ‘Byte Basket of India’. 

With a population of around eight million, Bengaluru is one of the fastest-growing 

cities in Asia. Many international fi rms have set up offi ces here. Despite the rapid 

pace of modernization, Bengaluru has retained its natural charm, with its parks 

and historic buildings. This is something that Rohit Pereira appreciates about his 

hometown: ‘A tour of Bengaluru can be very varied, taking you past palaces, museums, 

temples, churches and parks. Although the city is growing very fast, it is 

still one of the most elegant metropolises in the whole of India. It is a very attractive 

place and a cultural melting pot. The climate is also very pleasant all year round 

because the city lies 900 meters above sea level,’ the 35-year-old manager explains. 

In the evenings, he likes to relax on his terrace, from where he has a view over 

Bengaluru’s broad green spaces. 


35


Bengaluru with its eight 

million inhabitants is 

regarded as one of the most 

dynamic cities in Asia 

Pereira is head of the Indian branch offi 

ce of KÖRBER SCHLEIFRING. He and 

his twelve colleagues supply the Indian 

market with high-quality machines 

made in Germany and Switzerland. Al- 

though the competition from local 

grinding machine manufacturers is 

stiff, the SCHLEIFRING Group has a decisive 

advantage on the subcontinent: 

‘Our clients are looking for high-end 


THE INDIAN ECONOMY 

GDP by sector 07/08 in % 

Banking, 

insurance, real 

estate 

Public administration 

Retail, hotels, 

transport, storage, 

communications 

Agriculture 

Mining 

Construction 

Electricity, gas, water 

Manufacturing 

Service-orientated: Since the start of deregulation in the 

early 1990s, manufacturing and the service sector in 

particular have expanded rapidly. By contrast, agriculture 

precision solu- now accounts for only 17.6 per cent of GDP. 

tions, which local 

manufacturers 

are not able to 

supply. When it comes to requirements in the areas of micro- and nanotechnology 

they turn to KÖRBER SCHLEIFRING. We offer them turnkey solutions 

and reliable service,’ says Pereira. The list of clients ranges from small and 

medium-sized manufacturers of machine tools and ball bearings to companies 

in the aircraft, gas turbine and automotive industries, and even state-owned 

corporations. 

The SCHLEIFRING team in India (from left): Panduranga L., N. Raghuram, S. A. Madabhavi, S. N. Raveendra, Rohit Pereira, B. V. 

Giriyachari, Nelson Marianathan, Umesh N. V., H. Prabhakar, Usha Ramakrishna; Insets: Ashish Kamat (l.) and C. R. Sudheendra 

14.3 

13.4 

25.3 

17.6 

16.5 

2.6 

8.5 

1.8 

A tourist attraction in 

India’s high-tech 

metropolis: The 

20-meter-high Shiva 

statue in Bengaluru 

Source: gtai

� Securing long-term 

collaboration with clients 

Busy manager Pereira believes there 

are still plenty of opportunities on the 

Indian market for the SCHLEIFRING 

Group: ‘Our team here in Bengaluru is 

excellently placed to offer clients fl exible, 

individual solutions from the 

SCHLEIFRING Group’s entire range of 

products. It is important that we not 

only sell high-quality machines, but also 

impress customers with our good aftersales 

service. Then we can stay in contact 

with our customers and secure 

good, trusting collaboration with them 

over the long term.’ 

� Full of optimism 

Even though India’s economic growth 

has slowed slightly, Pereira is still full 

of optimism, because high domestic 

demand makes the Indian market less 

reliant on exports, and the government 

is continuing to invest in infrastructure. 

Further industrialization requires not 

only fi nancial resources, but also a large 

number of high-quality grinding ma- 

chines. ‘And we,’ smiles Rohit Pereira, 

‘are happy to continue supplying them 

to our customers all over India.’ 

INTERCULTURAL SKILLS 

A short guide to Indian 

business etiquette 

When in Rome, do as the Romans do. Anyone wanting to do 

business in India needs to respect certain basic rules. The most 

important of these are summarized in this guide to business 

etiquette. 

f you want to do business in 

I India, do not attempt to make 

new contacts in an imperson- 

al manner by email. A person- 

al relationship with your po- 

tential client is of the essence 

– business matters come later. 

Trade fairs, trips as part of a 

delegation, and existing contacts 

with other Indians offer 

good opportunities for establishing 

new contacts. 

Europeans on business trips to India need to be prepared for a different con- 

cept of time. Do not take it personally if your Indian counterpart is late – delays 

are part for the course. Never plan more than one meeting per day. By contrast, 

Indians expect business people from Germany and Switzerland to be punctual. 

It helps to allow an extra margin for time-critical business deals. When 

greeting a business equal you can shake him by the hand. If meeting an 

offi cial, you should wait to see which form of greeting he prefers. Only shake 

hands with an Indian woman if she initiates the handshake. Otherwise, you 

can bring your hands together with your fi ngertips just touching the under- 

neath of your chin, and bow your head slightly. This ‘namaste’ greeting is 

widespread in India. 

Doing business the Indian way: Personal contact is vital on 

the subcontinent 

Expressing direct criticism is regarded as extremely impolite on the subcontinent. 

Anyone who complains openly about failings will not be held in high 

regard. Instead, you should package criticism as praise and give constructive 

suggestions as to how results can be improved. Blowing one’s nose at table 

is seen as a faux pas. If eating with your hand, make sure you always eat with 

your right hand only. In India, the left hand is used for personal hygiene and 

is therefore regarded as ‘unclean’. 

Saying ‘no’ directly is also inappropriate. If you cannot comply with your Indian 

counterpart’s demands, it is better to use a phrase like ‘That could be 

diffi cult, but of course I will try.’ Remember that, by the same token, a ‘yes’ 

does not always indicate agreement. If you are unable to accept an invitation, 

you should fi nd a plausible reason for declining it – that way both sides can 

save face. For instance, offers of drinks are often declined initially. So it is 

quite acceptable to ask several times whether your Indian business partner 

is sure he does not want anything to drink. Likewise, if you are offered something, 

it is polite to wait until you are asked twice before accepting. 


37


SCHLEIFRING GRINDING SYMPOSIUM 2009 

Perfect performance 

Forum of experts: Prof. Straubhaar 

analyzed the economic situation 

The SCHLEIFRING Group confi rmed its 

technological leadership at the Grinding 

Symposium 2009 with strong manufacturing 

competence and in-depth industry 

knowledge. 

More than 1,000 participants per day, 

live presentations of the latest developments 

at 17 stations as well as fi ve 

technical conferences with a total of 20 

lectures by renowned industry experts. 

At the SCHLEIFRING Grinding Symposium 

2009 in May, the SCHLEIFRING 

companies demonstrated once again 

why they are among the world leaders. 

‘If you wanted to fi nd out what grinding 

machines are capable of these days, then 

the Grinding Symposium had plenty to 

offer,’ reported the trade magazine 

‘MaschinenMarkt’. 


� Clear message 

Live presentation: SCHLEIFRING 

innovations inspired the visitors 

Colorful program: Show performances and 

good atmosphere at the evening events 

Lively: Trade 

visitors 

discussed the 

latest grinding 

solutions 

In fact, the strong manufacturing competence and in-depth industry knowledge 

of the SCHLEIFRING Group was spectacularly presented in the Swiss town of 

Thun. The message was clear: the SCHLEIFRING Group continues to focus on 

technological leadership and is determined to meet the challenges of the global 

markets with innovative products and perfect performance. ‘Nowadays, the 

manufacture of high-precision parts requires machine tools which offer absolute 

quality and reliability as well as tailor-made solutions which are crucial in international 

competition,’ said Dr Ralf Kammermeier, Managing Director of Körber 

Schleifring GmbH. Prof. Thomas Straubhaar, head of the Hamburg Institute of

International Economics and speaker at 

the Symposium stated: ‘There are good 

reasons for an optimistic outlook for the 

German and Swiss industry. This is supported 

by the high competence and technological 

leadership of the companies.’ 

� Interesting mixture 

The concept of the conference was very 

well received by the trade (see right). 

Fifty-four per cent of visitors rated the 

Symposium as ‘extremely good’. The 

vast majority came to Thun in order to 

keep up to date with technological in- 

novations and the SCHLEIFRING Group 

in general. The interesting mixture of 

practical demonstrations, science and a 

colorful evening program in the Casino 

Kursaal Interlaken accounted for the special 

charm of the event. The visitors’ response 

was entirely positive. Eighty per 

cent of all participants were very to extremely 

satisfi ed with the SCHLEIFRING 

Grinding Symposium 2009. 

SURVEY ON THE GRINDING SYMPOSIUM 

How did you fi nd the GRINDING SYMPOSIUM overall? 

Extremely good 46% 

What was the purpose of your visit to the GRINDING SYMPOSIUM in 2009? 

(multiple answers possible) 

General information 74% 

Innovation/science 73% 

Networking 30% 

9% 

10% 

Procurement 

Other 

How well were your expectations met? 

Extremely satisfi ed 62% 

good 54% 

Very satisfi ed 18% 

�� 

�� 

�� 

�� 

�� 

�� 

�� 

�� 


Satisfi ed 20% 

39 

Source: Customer survey by KÖRBER SCHLEIFRING


MEDICAL TECHNOLOGY 

Keeping mobile 

Artifi cial knee joint: The 

HELITRONIC VISION 

combined with NXis 

Ortho software 

Modern orthopedic products preserve mobility. With its new NXis Ortho system 

WALTER offers manufacturers of components such as artificial joints cost-saving and 

speedy grinding solutions. 

From artifi cial knee joints to hip implants 

to spinal fusion plates – more 

and more people are dependent on implants 

as a result of accidents or physical 

decline. Their manufacture, however 

is rather expensive. Bio-compatible 

high-tech materials and extreme precision 

are essential for making perfectly 


fi tting artifi cial body parts. The technical challenge of manufacturing these components 

is therefore correspondingly high. The market for orthopedic implants 

is developing at a fast pace. The number of suppliers and products is rapidly 

increasing, making competition harder at the same time. In this sector too, the 

market demands lower manufacturing costs and we have a solution. One alterna-

tive for increasing effi ciency is computer-simulated 

production planning, 

followed seamlessly by actual production. 

The new WALTER NXis Ortho 

system facilitates such an optimized production 

process. 

� From concept to simulation 

Most suppliers of orthopedic technology 

design their parts using conventional 

CAD/CAM programs. After that, the 

manufacturers determine how the components 

should be made. Testing the 

prototypes is next. This, however, is a 

very time-consuming process. Often, the 

course of action has to be reassessed 

and partly redeveloped. 

The NXis Ortho system, on the other 

hand, goes directly from designing the 

parts to complete 3-D simulation of a 

machining program. Consequently, the 

design process and the manufacturing 

pro-cess take place simultaneously, reducing 

the time from conceptual planning 

to market considerably. The system 

combines the speed, precision and accuracy 

of the WALTER HELITRONIC 

VISION’s grinding process with an effi - 

cient new software interface. This facilitates 

the cost-effi cient development from 

3-D model to fi nished part. The program 

simulates a complete machine with grin- 

ding process, grinding wheels, tools and 

dressing equipment before the actual 

production process takes place, so that 

mistakes can be identifi ed in advance 

and rectifi ed. 

� Best surface fi nishes 

‘The HELITRONIC VISION is signifi cantly 

more productive than other tool grinding 

machines, making it ideally suited 

to the orthopedic sector,’ says Simon 

Manns, Applications Manager Tool Grind 

ing at the North American SCHLEIFRING 


+++ edward.sinkora@grinding.com +++ 

www.grinding.com +++ 

christoph.ehrler@walter-machines.com 

+++ www.walter-machines.com +++ 

Growing market: 

The joint implant 

business is booming 

First simulate, then manufacture: The NXis Ortho system ensures a competitive edge 

subsidiary United Grinding Technologies. The 3-D portal offered unsurpassed 

damping properties for optimum surface fi nishing, for instance for artifi cial knee 

or hip joints. The speed of the linear motors also minimized non-grinding time. 

Robby Faulkner, a colleague of Simon Manns explains: ‘We use a complete 3-D 

solid state simulation, which allows every user to check his manufacturing path on 

the PC.’ Grinding wheel dressing procedures can be easily confi gured with the 

NXis Ortho software. The 

man-machine interface auto- 

matically provides optimum 

dressing calculations and 

presents them as a guideline. 

‘NXis Ortho is the best approach 

to CAD/CAM on a 

grinding machine that I have 

ever seen,’ says Simon Manns. 

ADVANTAGES OF NXIS ORTHO 

Shorter processing times 

Better end product 

Versatility for a wide range of orthopedic 

components 

Fast programming and set-up 


41


WATCH- AND-CLOCK MAKING INDUSTRY 

Precise as clockwork 

High-tech movement: ment: 

The mechanism of a 

chronometer contains ntains many 

high-precision micro parts 


Single-tooth cutters: 

IWC Schaffhausen 

makes its own tools 

for watch 

manufacture 

The toolmakers at the Swiss 

watch manufacturer IWC 

Schaffhausen rely on EWAG 

tool grinding machines. 

They count the hours and set the pace 

for our day-to-day lives. Clocks used 

to be a sign of wealth, and only a few 

were able to afford their own timepiece. 

Today, everybody can afford one. In ad- 

dition, there are also many very valuable 

miracles of precision, the greater part of 

which come from Switzerland. No other 

nation generates as much profi t from 

the export of clocks and watches as the 

Alpine country. This is mainly down to 

high quality luxury watches, since measured 

against the number of watches 

Indispensable aid: 

Producing special tools on 

the EWAG WS 11

exported, Switzerland, with ‘only’ 25 million 

units falls a long way behind China 

(about 1 billion) and Hong Kong (about 

700 million). 

� Individual special tools 

The traditional Swiss company IWC 

Schaffhausen has been developing and 

manufacturing mechanical precision 

watches for over 140 years. One of the 

quality characteristics of IWC Schaff- 

hausen is that the tools for manufactur- 

ing the watches are all made in their own 

workshops. ‘We manufacture around 

250 new instruments and devices annually. 

Many of them are unique,’ explains 

Dieter Carld, who is responsible for the 

production of the cutting tools at IWC 

Schaffhausen. His department supplies 

the internal workpiece production, the 

case production, the pre-assembly and 

the watch assembly departments with 

single-tooth cutters, fi llet cutters, en- 

graving tools, prototype tools and special 

devices. Ninety per cent of the tools 

made, and the very individual requirements they have to fulfi ll. ‘We rely on the 

EWAG WS 11 for manufacture. It fulfi lls all our demands for minimum measurement 

tolerances and the highest levels of precision perfectly,’ reckons Dieter Carld. 

� Indispensable multi-talent 

For three years now, the manual universal grinding machine has been an indispensable 

part of manufacturing and regrinding high-precision miniature tools 

in the toolmaking shop at IWC. ‘The WS 11 can also be re-equipped quickly and 

very easily, which we value very highly particularly for individual tools for prototype 

construction, special manufacture and short runs.’ 

� Globally unique 

Performance perfection: 

Dieter Carld checks micro 

tools on the EWAG WS 11 

Thanks to the special axis kinematics, cylindrical and tapered tools can be ground 

are special tools. But what they all have and measured in a single clamping operation on the WS 11. ‘The arrangement of 

in common is the absolute precision of the axes is unique worldwide and allows all adjustments to be made in the work- 

a few micrometers to which they are shop. This means the WS 11 achieves unparalleled high precision and all-round 

performance. ‘The machine and its concept mean it is a simple 

matter for the operator to make or regrind high-precision micro 

LATEST INNOVATIONS ON THE WS 11 

tools,’ says EWAG Product Manager Herbert Gruner. The WS 11 

An easily-read control panel with emergency switchoff 

and ON/OFF switches for simultaneous start and 

can indeed grind tools with a diameter of 0.1 millimeter. A measuring 

table with special optics makes it possible to control the 

stop of workpiece and grinding spindle 

tool when it is clamped in position. Using the optics, which can 

Simple interruption of the grinding process for 

be adjusted to the μ, the operator can monitor the grinding pro- 

measuring or targeted workpiece correction thanks 

to the ON/OFF buttons 

Spindle drive with AC motor and frequency convertcess 

at a magnifi cation of up to 100:1 and check angles and diameters 

at the same time. ‘The WS 11 is a multi-talent, versatile 

er – no need to reverse the driving belt on the 

in application, easy to use, 

grinding spindle any more 

and – especially important FURTHER INFORMATION 

Continuous adjustment of the speed by potentiometer 

(grinding spindle 2,500–8,000 rpm; workpiece 

spindle 100–1,300 rpm) 

for us – it works with clockwork 

precision,’ concludes 

+++ herbert.gruner@ewag.com 

+++ www.ewag.com +++ 

Dieter Carld. 

www.iwc.com +++ 


43

Körber Schleifring GmbH 

Nagelsweg 33–35 

20097 Hamburg 

Germany 

Tel: +49-40-21107-03 

Fax: +49-40-21107-13 

info@schleifring.net 

www.schleifring.net 

Blohm Jung GmbH 

Kurt-A.-Körber-Chaussee 63–71 

21033 Hamburg, Germany 

Tel: +49-40-7250-02, fax: +49-40-7250-3287 

sales-hh@blohmjung.com, www.blohmjung.com 

Jahnstraße 80–82 

73037 Göppingen, Germany 

Tel: +49-716-1612-0, fax: +49-716-1612-170 

sales-gp@blohmjung.com, www.blohmjung.com 

Ewag AG 

Industriestrasse 4, 4554 Etziken, Switzerland 

Tel: +41-32-61331-31, fax: +41-32-61331-15 

info@ewag.com, www.ewag.com 

Fritz Studer AG 

3602 Thun, Switzerland 

Tel: +41-33-439-1111, 

Fax: +41-33-439-1112 

info@studer.com, 

www.studer.com 

Körber Schleifring Machinery Shanghai Co. Ltd. 

Beijing Branch Offi ce 

Room 10-04, CITIC Bldg. 19, Jian Guo Men Wai Da Jie 

Beijing 100004, China 

Tel: +86-10-6595-9934, fax: +86-10-6500-6579 

info@schleifring.cn 

Körber Schleifring UK Ltd. 

B13 Holly Farm Business Park, Honiley 

Kenilworth, Warwickshire, Great Britain 

CV8 1NP 

Tel: +44-1926-4850-47, fax: +44-1926-4850-49 

neil.whittingham@walter-machines.de 

info.wg@walter-ag.com 

Körber Schleifring Italia Srl 

Via G. Garibaldi, 118 

22073 Fino Mornasco (CO), Italy 

Tel: +39-031-926-262, fax: +39-031-926-261 

info.it@walter-machines.com 

Körber Schleifring 

Machinery (Shanghai) Co., Ltd. 

No. 1128, Taishun Rd, Anting Town 

Shanghai Jiading 201814, China 

Tel: +86-21-39587333, fax: +86-21-39587338 

info@schleifring.cn 

United Grinding Technologies, Inc. 

510 Earl Boulevard 

Miamisburg, Ohio 45342, USA 

Tel: +1-937-859-1975, fax: +1-937-859-1115 

ugt@grinding.com 

5160 Lad Land Drive 

Fredericksburg, Virginia 22407, USA 

Tel: +1-540-898-3700, fax: +1-540-898-2811 

Mägerle AG Maschinenfabrik 

Allmendstrasse 50, 8320 Fehraltorf, Switzerland 

Tel: +41-43-3556-600, fax: +41-43-3556-500 

sales@maegerle.com, www.maegerle.com 

Schaudt Mikrosa GmbH 

Hedelfi nger Straße 137 

70329 Stuttgart, Germany 

Tel: +49-711-4014-0, fax: +49-711-4014-290 

sales@schaudt.com, www.schaudt.com 

Saarländer Straße 20 

04179 Leipzig, Germany 

Tel: +49-341-4971-0, fax: +49-341-4971-500 

sales@mikrosa.com, www.mikrosa.com 

Walter Maschinenbau GmbH 

Jopestraße 5 

72072 Tübingen, Germany 

Tel: +49-7071-9393-0, fax: +49-7071-9393-695 

info@walter-machines.com, 

www.walter-machines.com 

Schleifring Service AG 

Thunstrasse 15 

3612 Thun, Switzerland 

Tel: +41-33-439-1212, fax: +41-33-439-1514 

info@serviceag.net 

Körber Schleifring Asia-Pacifi c PTE. Ltd. 

25 International Business Park 

#01-53/56 German Centre 

Singapore 609916 

Tel: +65-6562-8101, fax: +65-6562-8102 

michael.schmid@walter-machines.de 

Körber Schleifring France 

2 bis, Avenue du Président François Mitterrand 

91385 Chilly-Mazarin, Cedex, France 

Tel: +33-1-697921-21, fax: +33-1-697921-10 

commercial@schleifring.fr 

Körber Schleifring GmbH – India Branch Offi ce 

No. 99, Spencer Road 

First Floor, Frazer Town 

Bangalore 560 005, India 

Tel: +91-80-412504-25, fax: +91-80-55658-99 

sales@schleifring.in 

Schleifring Brasil Ltda. 

Av. XV de Agosto, 5.060 

Sorocaba, Brazil, CEP: 18085-290 

Tel: +55-15-322457-26, fax: +55-15-322813-66 

vendas@schleifring.com.br 

Schleifring Service GmbH 

Hedelfi nger Straße 137 

70329 Stuttgart, Germany 

Tel: +49-711-4014-100, fax: +49-711-4014-207 

info@servicegmbh.net

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