hp tooling 2020 #4

ISSN 2628-5444
high precision tooling
Machine Tools, PCD, PVD, CVD, CBN, Hard Metal 2020 - 4
■ New manufacturing approach in grinding ■ Laser process measuring technology for precision machining ■
■ New diamond-like carbon coatings ■ Saws with interchangeable teeth ■ New motor spindles ■

A must for every
Tool Grinding Service
The Pioneer invites you
Universal – Dia – Sharpening
Individual machine demonstration
can be arranged by appointment at email office@lach-diamant.de
® ®
https://bit.ly/3k6FDyT
www.lach-diamant.de

editorial
Against the trend
FILTECH
February 23 – 25, 2021
Cologne – Germany
Eric Schäfer
editor-in-chief
The trend word of the year is “cancelled”.
Shortly before editorial deadline,
GrindTec, International Trade Fair for
Grinding Technology, was also cancelled.
We were all looking forward to finally
being able to communicate with each
other personally again after many hours
of online seminars, zoom conferences
or virtual trade fairs and to be able to
take a look at new developments on site. For example, the
long-awaited laser machine from Vollmer.
Such laser processing possibilities of diamond tools or diamondcoated
tools are, to put it bluntly, trendy. As well as hybrid grinding
machine concepts that also integrate other manufacturing technologies,
and new 5-axis machine concepts for tool grinding.
The Filtration Event
www.Filtech.de
Platform
for your
success
One of tomorrow’s approaches is oxygen-free production in grinding,
which scientists at the Institute of Production Engineering and Machine
Tools IFW are working on. They present this new concept to our readers
in more detail starting on page 32.
This issue is also devoted in detail to the numerous new tool
presentations of the past months, which can help to optimize
your high-precision machining. Optimized processes are almost
unthinkable without suitable tool management. On page 46, an
example from international automobile production shows how
you can manage new and old tools in a tool management system,
even between different locations.
Eric Schäfer
editor-in-chief
Filtration
Solutions
for the
Processing
Industry
…and don’t forget to check www.harnisch.com!
Your Contact: Suzanne Abetz
E-mail: info@filtech.de
Phone: +49 (0)2132 93 57 60

table of contents
lead story
Diamond hardness & graphite lubrication combined
New DLC coatings 6
materials & tools
MRO tools weather turbulent industrial economy 8
New turning grades for cast iron and cast stainless steel 10
For large holes up to 96 millimeters 12
“Stainless package” now ready 13
Face milling cutters with suction effect 14
New innovative tooling solutions 16
SawTec 2.0 - saws with interchangeable teeth 17
Defined chamfering deburrs gear teeth in seconds 18
Tiger tec • ® pushes the boundaries 20
Precision diamond profile dressing rolls 21
LACH DIAMANT looks back on 95 years - 6 th part - Quo vadis - where are you going… ? 22
processes
Oxygen-free production: new manufacturing approach in grinding
Prof. Dr.-Ing. Berend Denkena, Dr.-Ing. Alexander Krödel and M. Sc. Nils Hansen 32
State-of-the-art laser process measuring technology for precision machining 38
Laser light makes VOLLMER a full-line supplier 40
Substantial time and cost savings in the maintenance management 41
machining center
Handling system HS flex heavy 42
New machining centers increase productivity and precision 44
components
Flexible 5-axis clamping system with two functions 45
Multi-site Tool Management 4.0 46
New motor spindles save users second machine 48
departments
fairs 5, 30
companies 26
impressum & company finder 50
4 no. 4, November 2020

fairs in alphabetical order with original date
AMB Stuttgart, Germany
(September 15-19, 2020)
bauma CHINA Shanghai, China
(November 24-27, 2020)
CCMT Shanghai, China
(April 7-11, 2020)
CIMT Beijing, China
(April 12-17, 2021)
EPHJ Genf, Switzerland
(June 16-19, 2020)
FABTECH Toronto, Canada
(June 16-18, 2020)
postponed to
September 13-17,
2022
not postponed,
2020
completely
cancelled
not postponed,
2021
June 8-11,
2021
June 14-16,
2022
FEIMEC São Paulo, Brazil
(May 5-9, 2020)
May 3-7,
2022
20222022
GrindTec Augsburg, Germany
(March 18-21, then November 10-13, 2020)
Hannover fair Hanover, Germany
(April 20-24, 2020)
IMT Brno, Czech Republic
(October 5-9, 2020)
IMTS Chicago, USA
(September 14-19, 2020)
intertool Wels, Austria
(May 12-15, 2020)
JIMTOF Tokio, Japan
(December 7-12, 2020)
METALEX Bangkok, Thailand
(November 18-21, 2020)
Metalloobrabotka Moscow, Russia
(May 25-29, 2020)
March 15-18,
2022
2021 April
analog, digital and
hybrid
September 13-17,
2021
September 12-17,
2022
May 10-13,
2022
virtual online
exibition
not postponed,
2020
May 24-28,
2021
Metallurgy Russia + Moscow,
Litmash Russia (June 9-11, 2020)
Russia
June 8-10,
2021
METAV Düsseldorf, Germany
(March 10-13, 2020)
SIMTOS Goyang, South Korea
(March 31-April 4, 2020)
Stone+tec Nuremberg, Germany
(June 17-20, 2020)
Surface Stuttgart, Germany
Technology (June 16-18, 2020)
TIMTOS Taipeh, Taiwan
(March 15-20, 2021)
TMTS Taichung, Taiwan
(November 10-14, 2020)
trade fair dates as by beginning of October, 2020;
we are not responsible for reliability of these dates
March 23-26,
2021
postponed, 2022
May 12-15,
2021
June 21-23,
2022
not postponed,
2021
virtual online
exibition
no. 4, November 2020
5

lead story
PLATIT’s new DLC coatings
Diamond hardness &
graphite lubrication combined
written by Dr. Hamid Bolvardi, Dr. Jan Kluson, Mojmir Jilek, Christian Galamand
and Dr. Andreas Lümkemann
Diamond-like Carbon (DLC) coatings have unceasingly
absorbed overwhelming interest from
industry as well as academic research institutions
within last years.
High hardness and elastic modulus, chemical inertness,
optical transparency, superior tribological properties and
good corrosion resistance as well as high biocompatibility
and resistance to bacterial colonization make DLC an engrossing
coating system. Owed to the unique and broad
range of properties, DLC coatings are constantly employed
in new applications from cutting and forming tools to
components; saw blades, end mills, micro-tools, punches,
injection and extrusion molds and dies, automotive,
decorative, medical applications are just few raised examples
here.
PLATIT’s coating portfolio comprises three DLC coating
types which are aimed and fine-tuned to address
specific market and application needs (figure 1). DLC 1 and
DLC 2 are hydrogen containing and DLC 3 is the hydrogen
free coating generation [1, 2]. DLC coatings consist of
a mixture of sp 3 (diamond) and sp 2 (graphite) bonds. The
higher sp 3 bond fraction results in a higher density, hardness
(at ambient and elevated temperature), thermal stability,
oxidation resistance, higher residual stress and lower
thermal conductivity [3, 4, 5]. DLC 3 (ta-C) with the highest
sp 3 content, i.e. > 50 %, is fine-tuned mainly for tools and
particular components. DLC 1 and DLC 2 are specifically
aimed to address application challenges in components
and sliding contacts.
PL711 DCMS & HiPIMS coater:
dedicated design, high productivity
The PLATIT’s PL711 coating machine is an ideal solution
with a new dedicated design for coating components with
DLC at high productivity and low maintenance intervals.
Despite of all DLC acquainted advantages, typically DLC
coating machines would require cleaning intervals which
leads to additional costs and machine downtime. Along of
PLATIT’s PA3D module (new designed lateral Helmholtz
coils) carbon plasma will be confined to carousel as schema
tically illustrated in figure 2. This innovative design will
significantly reduce the chamber contamination and increase
the deposition rate and productivity, i.e. an ideal
design specially for hydrogen containing DLC coatings.
figure 1
PLATIT’s DLC coatings portfolio
figure 2
PLATIT’s PL711 highly productive DCMS & HiPIMS coater
Pi411 PLUS arc and sputtering coater:
ultra-flexible
Due to its modular design and the range of available technologies,
e.g. arc, sputter, PECVD, OXI processes, Pi411
PLUS is the world’s most flexible coating unit. PLATIT’s
new DLC 3 (ta-C) is a sputtered coating with SCIL ® technology
requiring no hardware change in Pi411 PLUS coater
compared to prior or later nitride or oxynitride batches.
6 no. 4, November 2020

lead story
References
[1.] www.platit.com
[2.] Compendium - PLATIT
AG
[3.] M. Kamiya et al.,
Vacuum 83 (2009),
page 510 - 514
[4.] A.C. Ferrari et al.,
Appl. Phys. Lett. 75 (1999),
page 1893 - 1895
[5.] R. Kalish et al.,
Appl. Phys. 74 (1999),
page 2936 - 2938
[6.] T. Cselle et al.,
Werkzeug und Technik,
no 183, August 2020
figure 3 - DLC 3 coated endmill under scanning electron microscope
PLATIT’s sputtering SCIL ® technology with
unique rotating cathodes, enables the synthesis
of the new high quality DLC coatings (figure 3).
High magnetic field strength inside the SCIL ®
sputter cathode and its very efficient target
cooling together with substrate heat management
during deposition fabricate the hardest
sputtered ta-C on the market as of today. Hardness
value of 45 - 50 GPa and > 50 % sp 3 content
are features of PLATIT’s new DLC 3 . Along with
achieved high coating hardness values, good
productivity and low coating machine maintenance
intervals are maintained.
Compared to other ta-C synthesis methods
like filtered cathodic arc, where higher hardness
values are theoretically feasible, SCIL ®
sputtered DLC 3 has a much higher productivity,
i.e. deposition rate. Additionally, deposition
process runs more stable and coating small size
tool geometries as we have for micro tools is
realizable without the risk of overheating and
adverse effects thereof.
Figure 4 exhibits superiority of ta-C combination
of high hardness and low friction in
case of a DLC coated moving ceramic part of
a water tap. This allows for much higher lifetime,
which is the number of opening and closing
cycles, at a lower and stable friction torque.
The PLATIT’s fine-tuned DLC coating portfolio
allows for a pertinent choice for each application
ranging from tribological and sliding contacts
to micro-cutting tools. For further technical
information and DLC coatings performance
in diverse applications please refer to references
1 and 2 or contact PLATIT AG.
figure 4
Comparison of the frictional torque of different DLC-coatings
on a ceramic closure wear element in a water tap [6]
PLATIT
is an independent, family-owned company headquartered in Selzach,
Switzerland as well as a leading manufacturer of high-tech PVD and PECVD
hard coating equipment for tools and machine components. With over
550 installed systems worldwide, own service, support and sales
offices in Europe, North America and Asia, PLATIT maintains
close partnerships with its customers.
further information: www.platit.com
no. 4, November 2020
7

materials & tools
Continual requirements:
MRO tools weather turbulent industrial economy
The metalworking industry has experienced
both positive and negative periods of economic
development in recent years. This is often linked
to the performance of several key industries, such
as automotive, aerospace and oil & gas. However,
there is one segment which seems to weather the
storm regardless of the economic climate - Maintenance,
Repair and Overhaul (MRO).
Regardless of whether times are good or bad, many industrial
companies have continual requirements for maintenance
and to support production operations. Their primary
aim is to find alternative options to keep costs low by reusing
existing equipment or materials, repairing items or
simply choosing a cheaper option to get the job done.
The latest report by business intelligence provider
Visiongain says that Europe’s MRO market reached spending
of $ 170 billion in 2019 and is expected to grow at an
annual rate of two percent. [https://www.visiongain.com/
report/europe-maintenance-repair-and-overhaul-mro-marketreport-2019-2029/]
A key feature of MRO is hand-drilling operations, particularly
standard high-speed steel (HSS) drills, which
represent the lifeblood of the segment. Dormer Pramet is a
leading manufacturer of HSS and HSS-E general purpose
drills, with more than 100 years’ experience of providing
cutting tools to meet companies’ MRO needs.
The most popular ranges within its Dormer assortment
include jobber length and stub length drills for use in
hand-held power drills, pillar drills and other manually
operated machinery. Its stub length drills, for example,
feature shorter flutes to increase toughness and precision.
This makes them ideal for tight spaces and hand-held
operations that require
rigidity. In addition, the
shorter length reduces
deflection, breakage and
runout.
However, when performing
hand-held applications,
the length of the
drill is not the only important
criteria to consider
when choosing the
right cutting tool. Consistent
and predictable
per formance is critical,
meaning the right geometry
and torque capabilities
are paramount.
Torque
The drilling torque is predominantly determined by the
workpiece material properties, diameter, drill geometry
and machining parameters. From the machining parameters,
the feed is the main factor to consider, because cutting
speed has little influence on the development and size
of the cutting forces.
With modern CNC machine-tools the drilling torque is
rarely a limiting factor, but with light duty machines,
pillar drills and hand-held power drills it is a
primary consideration.
When torque becomes a limiting
factor, a reduction of the feed per
revolution is needed or alternatively
a change to a twostage
operation. This
means pre-drilling
with a smaller sized
drill (≈ 0.2 x D),
followed by
drilling with the
desired diameter.
Point Geometry
In general CNC machining environments, maximizing
drilling speed, while maintaining required hole-quality, is
often favored as it can result in greater cost savings. However,
for the MRO engineer, safety and reliability is paramount.
It is therefore important to understand the connection
between the features of the drill-point geometry
and the allowable penetration rate.
The rake angle, for example, is measured at the peripheral
corner and approximately equal to the lead of helix.
HSS drills group A123, A147, A723
The legendary
Dormer A002
general purpose
jobber length drill
8 no. 4, November 2020

materials & tools
However, it changes along the length of the major cutting
edge, getting smaller to eventually become negative near
the drill axis. This improves the sharpness of the drill,
which in turn, reduces the amount of torque required.
Just like the rake angle, the clearance angle also changes
in the radial direction. But where the rake angle decreases
from the peripheral corner to the drill axis, the clearance
angle increases. This helps to create a smooth exit hole
during hand-held operations.
The chisel edge is the first point of contact, pushing into
the material. However, it doesn’t cut the work-material, but
instead displaces it while penetrating. As a result, the chisel
edge creates most of the thrust forces exerted. The geometry
of the chisel edge, together with the point angle, determines
the centring characteristics which control hole positioning,
size and straightness.
Versatile cutting tools
A cutting tool which features these characteristics is the
popular Dormer A100 HSS drill. Suitable for drilling a variety
of materials, such as steels, aluminum and stainless
steel, the versatile A100 is ideal for hand-held applications.
Its strong 118-degree standard point is easy to re-grind and
a steam oxide finish prevents the work-piece material from
sticking to the cutting edge.
Also, the legendary Dormer A002 general purpose jobber
length drill, developed more than 20 years ago, continues
to be sold in huge quantities around the world. Providing
a smooth cutting action and consistently high quality, in
a wide variety of materials, its self-centering split point offers
excellent positional accuracy.
Its lesser known cousin, the A108, features a split point
and a quick-spiral helix specifically for machining stainless
steel. A sharp geometry limits the onset of work-hardening
and a steam tempered surface treatment helps retain
cutting fluids and prevents material sticking to the cutting
edge. Manufactured from M2 grade of HSS, which is one
of the toughest available, make it ideal for hand-held operations.
The Dormer A777 and A117 high speed cobalt jobber
and stub drills provide another option for hand drilling.
Their heavy-duty design makes them suitable for machining
high-tensile, tougher materials, such as tool steels. A
135-degree split point design helps with self-centering
when used by hand and reduces the push force required.
A bronze oxide finish prevents work-piece material from
sticking to the cutting-edge during usage.
Hand-held tools
In addition to standard jobber drills, Dormer Pramet has
a range of cutting tools for other hand-held applications.
Spot weld drills are one of the most common used in MRO
applications, especially when replacing sheet-metal panels
welded together. Removing a spot weld with a standard
twist drill can be messy and dangerous because the drill
can wander on the hardened, uneven surface.
HSS drills action
However, the A723 high-speed cobalt spot weld drill is
available in several standard sizes to suit common applications
in the automotive and trailer repair industry. A
special lip and spur point provide accurate centering by
preventing the drill from wandering. In addition, a sharp
outer-corner cuts the softer material around the spot weld
at the same time.
A strong web design gives strength for improved penetration
in tough conditions and ensures a safe and reliable
use. Short flute options enhance rigidity for the hand-held
drilling of thin panels and sheet steel, increasing stability
even more.
Finally, high speed steel (HSS) sheet metal drills are
available in several standard sizes to suit common rivets,
screws and bolts. Suitable for drilling thin sheet steel and
panels, the A123 range features a 120 °-point geometry
with a short flute to provide easy penetration and rigidity
in portable applications. No body clearance further increases
stability during drilling and breakthrough to give
superior hole quality.
Its thin web at the point provides excellent self-centering
properties, while its steam tempered surface improves
performance and reduces the chance of built-up edge. An
economical double-ended version (A119) is also available,
helping to reduce inventory costs.
Dormer Pramet’s wide collection of economical holemaking
tools is supported with additional options, such as
threading taps and rotary carbide burrs. This demonstrates
the company’s commitment to the MRO segment, helping
to ensure it continues to develop no matter what the market
conditions.
further information: www.dormerpramet.com
no. 4, November 2020
9

materials & tools
New turning grades for cast iron and
cast stainless steel
Mitsubishi Materials has expanded its comprehensive
range of premium insert grades for turning.
BC5110 is a specially coated CBN specifically
for machining grey cast irons such as GG25 and
GG30. Whereas the MH515 grade is a CVD coated
carbide grade designed for cast austenitic stainless
steels as well as ductile cast iron.
The new BC5110 delivers a variety of performance and
benefits by drawing on the vast R&D work built up over
years of producing other high performance CBN grades.
This work has created a composition of a fine grain, high
CBN content substrate that greatly improves chipping resistance.
This results in process reliability and longer tool
life. Meanwhile, the hard ceramic coating layer adds to the
user benefits by providing wear and notching resistance to
help machine excellent component surface finishes.
In addition to a wide selection of both positive and negative
geometry inserts for BC5110, two different edge honing
types, the FS and GS, are available to help machine
programmers and tooling engineers select the ideal insert
for their application. The FS honing has a sharp edge
for reduction of burrs and displays excellent resistance to
flank wear. The GS type is suited to thin or low rigidity
components and is resistant to edge chipping.
The innovative new carbide grade MH515 has been specially
designed to meet a niche range of applications. An
Al 2
O 3
TiCN
carbide substrate
Coating features of MH515
Tough Grip layer
Nano-texture
coating
Tough Grip layer
advanced coating ensures improved peeling resistance
and edge life for machining cast austenitic stainless steels
and ductile cast materials typically found in turbocharger
housings. The key to the jump in performance and reliability
comes via the Tough Grip technology that maximises
the binding between the coating layers. A top layer of
Al 2
O 3
and a lower TiCN layer that displays advanced levels
of adhesion to the carbide substrate, in combination with
optimised crystal growth Nano-texture technology works
together to provide a tough cutting edge. This toughness is
necessary to deal with the difficult conditions of cast turbocharger
housings and in addition provides outstanding
wear and chipping resistance to bring process reliability
and more parts machined per edge.
MH515 inserts are available in negative and positive geometries
with four different chipbreakers, LK for light machining,
MA and GK for medium cutting and RK for rough
machining.
MH515
BC5110
further information: www.mmc-hardmetal.com
10 no. 4, November 2020

materials & tools
DWAE drills for Swiss
and automatic lathes
DWAE drills have been specifically designed
for drilling in the confined spaces of Swiss type
and automatic lathes. Several important parameters
were set before they were launched. The most
important of these parameters was low cutting
resistance, to provide reliability and excellent
chip control, which is necessary to prevent chips
wrapping the component and clogging the confined
work spaces. To achieve this, several features
were built into the geometry, substrate and coating
of the drills.
Optimum cutting edge and flute design
Mitsubishi’s wavy type cutting edge is utilised because
this provides both sharpness and cutting
edge strength by resisting wear to the outer cutting
edge. This geometry also provides an even load
for the ideal solution to successfully machine low
rigidity workpieces. The efficient geometry of the
flutes helps to reduce the cutting forces, because
chips are broken into smaller and more manageable
pieces. In addition, the flute length has been specifically
engineered in shorter than conventional
lengths to meet the compact needs and limited
space of small CNC lathes. To complete the combination
of features that provide the low cutting
force and efficient chip breaking, there is the special
Z form web, thinning at the point of the drill.
The substrate and coating technology
To complement all the advanced geometrical features,
a carbide grade, DP102A, was developed to
optimise the overall performance and reliability of
the DWAE series. A substrate with an ideal balance
of hardness and toughness was used and a suitable
PVD coating was added to provide wear resistance
to the substrate’s natural fracture resistance.
The coating was found to be particularly effective
against wear at medium to low cutting speeds. A
smoothening treatment has also been applied to
the surface of the drills to further reduce binding
with the work material and to also facilitate excellent
chip disposal. This feature helps especially because
the drills are fed only with an external coolant
supply. In cutting tests when drilling DIN CF53
material with external coolant, at Vc (m/min) 80
with a feed rate of fr (mm/rev) 0.2, the DWAE drill
gave more than double the tool life compared to
other similar products.
Availability and choice
The drills are available in a wide range of sizes from
Ø 3.0 through to Ø 14 in 0.1 mm increments and in
both 2 x D and 4 x D flute lengths. For ease of use,
the shank diameters are also made to suit standard
collet sizes.
PVD coated grade DP102A,
for wear resistance
wavy cutting edge,
for extra sharpness
zero-µ smooth surface,
for reduced friction
Z thinning point,
for less cutting force
further information: www.mmc-hardmetal.com
no. 4, November 2020
11

materials & tools
For large holes up to 96 millimeters
Process-secure and high-performance
drilling up to a diameter
of 96 mm one single operation
- a common request from
a wide range of sectors - is fulfilled
by the KUB Pentron CS
indexable insert drill from
CERATIZIT, which is equipped
with an advantageous cartridge
system.
The KUB Pentron CS will be available
from stock when the machining
specialist publishes its new
Up2Date supplementary catalogue
this autumn.
The KUB Pentron indexable insert
drills from the KOMET range have
proven their worth over many years
in numerous industries. However,
the standard tools were limited to a
diameter range of 14 to 46 mm - too
little for many users. For large holes
(e.g. for bearing seats), they would
like to use similar, reliable, highperformance
KUB Pentron drilling
tools. Which is why CERATIZIT
decided to develop a new KUB Pentron
CS (CS = Cartridge Solution)
designed for large diameters up to
96 mm and a length to diameter
ratio of up to 3 x D.
Thanks to its modular structure,
the KUB Pentron CS is suitable for
universal use and for many special
applications. It consists of a burnished,
wear-resistant KUB Pentron
base holder in the accustomed high
quality from KOMET. CERATIZIT
has turned to the proven KOMET
ABS system for the coupling system
on the KUB Pentron CS, as it offers
significant advantages compared to
other interfaces, such as the cylindrical
shank, especially for large
holes. These include a higher clamping
force and torsional stiffness as
well as better values with regard to
force transmission, accuracy and
machining performance.
Two, high-precision cartridge seats are located in the base body. While the
inner cartridge is able to cover a specific diameter range, the outer cartridge determines
the bore diameter. Each cartridge contains two SOGX indexable inserts
from the CERATIZIT standard portfolio, which offers a huge selection.
The optimum cutting insert for every material and application can be found
there - with respect to the substrate, coating and special geometries, such as
those for better chip control.
further information: www.ceratizit.com
12 no. 4, November 2020

materials & tools
“Stainless package” now ready
Universal, wear-resistant, tough
The new CERATIZIT CTCM120 and CTCM130
carbide grades with innovative Dragonskin coating
ensure optimum turning performance with
stainless steels.
For turning stainless steels - regardless of whether they
be cast iron blanks, forged parts or semi-finished parts -
CERATIZIT is sure to have the optimum cutting insert
in its range. In addition to the established CTPM125 carbide
grade, two new cutting materials now round off the
product range: the more wear-resistant CTCM120 and the
tougher CTCM130. Thanks to the latest Dragonskin coating,
both grades are high performers and process-secure.
With the publication of the new Up2Date supplementary
catalogue, the machining specialists are launching two
new carbide grades which are recommended for turning
austenitic, stainless steels and supplement the existing allrounder
cutting material. Development focused on the
most frequently used stainless steels V2A (e.g. 1.4301) and
V4A (1.4545). The aim was to provide the user with a wider
selection of cutting inserts, which perfectly and seamlessly
cover every application - from roughing to fine machining.
The universal PVD-coated carbide grade CTPM125 has
proved its worth over many years. It is characterised by a
well-balanced ratio between toughness and elevated-temperature
hardness and promises to deliver high reliability
when machining all stainless steels.
The new addition to the range is the CVD-coated, highly
wear-resistant cutting material grade CTCM120, which allows
high cutting speeds with austenitic steels and boasts
a smooth cut. It also impresses with its long tool life
which in some cases was double that of the competition in
benchmark tests.
The particularly tough CTCM130 carbide grade, which
CERATIZIT recommends for interrupted cuts, for example,
is also new. If cutting speeds need to be kept low and conditions
are unstable, it helps to increase process security.
The complete range for austenitic, stainless steels is
characterised not just by the precise coordination of the
three grades, but also by the free selection of different
chip breakers.
Depending on their application, customers can choose
from three geometries for negative indexable inserts or
two for positive inserts - across all three cutting material
grades. Thus CERATIZIT has seamlessly covered all
application ranges for machining austenitic, stainless
steels.
Anzeige HP tooling 10_2020 210X78mm englisch_Layout 1 15.10.20 10:49 Seite 1
further information: www.ceratizit.com
IGUANA
MR BRILLIANT
The evolution of our high-end multi-cutter in the
small diameter range with diamond-coated,
laser-sharpened cutting edges - now also available
with helix and through-tool cooling.
The sharpest of its kind.
www.zecha.de

materials & tools
Face milling cutters with suction effect
Component interiors remain virtually chip-free
In October, Ceratizit introduced its PCD
MaxiMill SEC12 face milling cutter to the market.
The milling cutter is ideal for machining crankcases,
cylinder heads and other components made
from aluminium and non-ferrous metals found
in the automotive industry, the interiors of which
must remain chip-free. The special design of the
insert seat and cutting insert topology, supported
by the coolant pressure, creates a suction effect
that at high speeds clears virtually 100 % of the
chips away from the workpiece.
Anyone who works in engine manufacturing will be familiar
with the problem: during the conventional face milling
of crankcases and cylinder heads, chips fall into the water
chambers and get stuck there to such an extent that they
cannot be completely removed by the automated washing
process. They must be laboriously removed by hand, which
involves additional time and costs. And if chips remain,
the expensive component might even have to be scrapped.
Special features of the MaxiMill SEC12, like cutting edge
geometry, cutting edge positioning and coolant jet, generate
a suction effect for up to 100 % chip-free components
The new PCD MaxiMill SEC12 (Suction Effect Cutter/
cutting insert size 12) face milling cutter eliminates this
problem and saves both time and costs. Thanks to cutting
inserts with a ground-in chip removal notch and their
clever positioning in the body of the milling cutter, the
tool develops a suction effect that clears the chips away
from the component. The working angle from the flat surface
is approximately 30 degrees, which means that hardly
a single chip can enter the interior of the component. The
chip diversion is supported by the coolant flow, which applies
the optimum pressure behind the chips thanks to the
special way it is channelled.
CERATIZIT MaxiMill SEC12 also offers numerous other
advantages. One of the most important is its modular
design (made entirely of stocked standard components),
which enables individual versions to be created for any requirement.
The milling cutter consists of a milling adapter
in HSK-A63, -A80 or -A100 design, which holds the base
The MaxiMill SEC12 generates a new level of process
security, performance and cost-effectiveness
for the automotive industry
Conventional face milling vs. face milling with MaxiMill SEC12 with suction effect for virtually chip-free components
14 no. 4, November 2020

materials & tools
The MaxiMill SEC12 offers above-average long service life, modular tool design made up entirely of standard products,
requires no adjustment due to 100 % plug and play and provides uncompromising face milling
of cylinder heads and crankcases
body of the face mill. These are available in diameters of
50 Z6, 63 Z8, 80 Z10, 100 Z12, 125 Z14 and 160 Z18 mm,
which guarantees ideal, cost-effective machining results.
Further sizes and variants that are customised to individual
requirements are available on request.
The PCD inserts are characterised by an extremely long
service life above the usual market standard and cutting
speeds of up to 3500 m/min. Refinements in the geometry
of the cutting insert enable feed rate values of 0.1 to
0.2 mm per tooth. The number of teeth has been calculated
to match the power of standard machining centers
available on the market. CERATIZIT is offering two variants
for roughing: one for up to 8 mm width of cut and
one for maximum 4 mm width of cut that reduces costs
due to a lesser amount of PCD being used. This means that
customers can independently configure the optimum tool
for their application and machine.
Assembling the CERATIZIT MaxiMill SEC12 is a simple
plug & play solution: even the inserts can be fitted without
the need for adjustment thanks to their precision manufacture.
For particularly stringent quality requirements,
users can fine-balance the tools using the heavy metal
screws on the milling cutter flange - up to a balance quality
of G2.5. The resulting high radial run-out accuracy preserves
the spindle, guarantees a longer tool life and lower
vibrations and even enables a surface quality of approx.
Rz = 20 µm during roughing.
The roughing portfolio of the new Ceratizit MaxiMill
SEC12 will be in stock from October - a finishing port -
folio will follow shortly after. This standardisation has further
advantages such as permanent availability and an excellent
price-performance ratio.
MaxiMill SEC12 impresses
with its practical application
The MaxiMill SEC12 «milling cutter with suction»
yields impressive results in practice, for example
during the three-sided face milling of a crankcase
made from AlSi7MgCu0.5. The variant with a
diameter of 125 mm (12 teeth) is used here.
The most important cutting data:
♦ cutting speed Vc = 2355 m/min
♦ feed rate per tooth fz = 0.2 m/min
♦ feed rate Vf = 14,400 mm/min
♦ cutting depth ap = 5 mm
♦ cutting width ae = 80 %
This means that 40,000 components can be
machined per tool lifecycle in an impressive time,
to a high quality and virtually chip-free.
further information: www.ceratizit.com
no. 4, November 2020
15

materials & tools
New innovative tooling solutions
Long tool life as well as high performance
With the new KPK series and the MFWN mini
series, Kyocera is adding two new product lines to
its highly successful cutting tool product lines.
Kyocera is known for its innovative tooling solutions. Long
tool life as well as high performance are also the advantages
of the two new technologies, which extend the existing
line: the KPK series is well prepared for high-performance
cut-off solutions and strong clamping mechanism
for added safety and security. The MFWN mini series is a
smaller version of the original cutters, which also offer excellent
performance and tool life.
KPK series
insert uses three contact surfaces to ensure safe clamping
which eliminates chattering completely and makes the
cutting-off process a lot safer.
The unique chipbreaker technology is inherited from the
KGD lineup and provides excellent chip control. Thanks to
this advanced technology tool life is longer and machining
stable. The rigid tool holder block not only prevents
chattering but also provides an internal coolant which
also adds to the tool life even under normal pressure.
The MFWN Mini cutters convince
like the original
With the low
cutting force
90 ° milling
cutter with
double-sided
6-edge inserts, Kyocera launches a new mini series with a
smaller diameter than the original MFWN milling cutters.
The new line is based on the original, the MFWN milling
cutter, but is in no way inferior to it. On the contrary, the
mini series works at up to 5 mm D.O.C., while the large
model can be used at a cutting depth of up to 8 mm. This
product is also used for machining materials such as steel,
stainless steel, cast iron and exotic materials.
The KPK series ensures stable and safe cutting
When it comes to cutting operations in general, the workpiece
can be difficult to secure which leads to rigidity and
chattering issues. Therefore, the cutting speed is usually
low at the workpiece rotation center. Also, tools tend to
be broken easily by chip troubles. All these issues are long
gone with the KPK series as it features a new insert, blade
and a tool block design for rigid, safe and speedy cut-off
operations in the fields of steel, stainless steel, cast iron
and aluminium. Due to the easy insert replacement, the
down time is reduced to a minimum. The firmly secured
MFWN mini series
The design is based on the original MFWN series with
fracture-resistant inserts, low cutting forces and neutral inserts
for various uses. Another plus is the insert lineup. It
is comprehensive for various machining applications. In
total there are three insert chipbreakers and four grades
available. Namely for general use GM, for low cutting force
SM and tough edge GH. Additional fine pitch and small
diameter toolholders are available.
further information: www.kyocera.co.uk
16 no. 4, November 2020

materials & tools
SawTec 2.0
Saws with interchangeable teeth
Austrian carbide and tool specialist Boehlerit, whose development
expertise is based on its close connection to the steel industry, is exploring
new paths when it comes to sawing and launched the “SawTec 2.0”
tool system with interchangeable teeth, an intelligent, next-generation
machining solution.
Saw blades are used by the
metal-processing industry all
over the world for separating
rods, blocks, pipes, rails and
profiles. In most cases, saw
teeth are welded on, which
is labour-intensive and costly
especially for large saw diameters,
given the need for resharpening
and the logistics
involved.
Boehlerit has reacted to
this situation by creating the
innovative “SawTec 2.0” tool
system, which offers a solution
for large-diameter saw
blades, using screw-mounted,
interchangeable saw teeth. A
tangible benefit of this product
is that the screw-mounted,
carbide saw teeth of the
SawTec 2.0 are easy and quick
to exchange. The patented
“SawLock ® ” clamping system
ensures stability, efficiency,
precision and a high degree
of flexibility. A range of tooth
geometries is available to enable
users to choose the right
blade for steel, stainless steel
and highly heat-resistant steel,
depending on the material to
be sawn.
Sawtec 2.0 - saws with interchageable teeth
The initial programme consists
of interchangeable teeth
with a width of 9 mm, in three
cutting geometries (SP, SM,
SS) and two cutting grades
(BCP40X and BCM40X), suitable
for all standard steel, stainless
steel and highly heat-resistant
alloys. The interchangeable
teeth come with a state-of-theart
coating that increases the cutting surfaces by up to 200 % in m 2 , while increasing
the cutting speed at the same time. Saw blades are available in a diameter range
of 600 to 1500 mm, with the drilling hole for holding the spindle being executed
according to customer requirements.
Users who need to keep an eye on costs for their sawing operations and are looking
for a cost-effective solution will make the right choice with the “Sawtec 2.0”
tool system with interchangeable teeth by Boehlerit.
further information: www.boehlerit.com
no. 4, November 2020
17

materials & tools
Defined chamfering deburrs gear teeth in seconds
Particularly suitable for high volumes
Paul Horn GmbH has developed a process for
precision deburring of gear teeth that represents a
further advance in the world of gear production.
Although gear teeth can be deburred relatively easily with
brushes and discs, higher levels of precision and quality are
being demanded, with the result that there is often no longer
any scope for undefined chamfers at the tooth edges.
So Horn has developed a technology - together with the
associated production process - to enable the production of
defined chamfers.
It can be used, for example, to create a 45-degree chamfer
on both sides of a module 1 gear wheel with 25 teeth
in less than five seconds. A turn-mill center with synchronised
axes is required for this production process. However,
users do not need any special workholding equipment.
The solid carbide tools can be clamped in a standard collet,
or in shrink-fit or hydraulic chucks. The process is particularly
suitable for machining gears in high volumes. The
milling cutters are special tools and have to be individually
designed for each gear tooth. Based on the application,
Horn engineers will design the appropriate cutting edge
geometry for the module, tip diameter and desired chamfer.
Horn supplies the process data required for machining
together with the cutter.
Tool costs are low and quickly pay for themselves thanks
to short machining times. The carbide substrate, tool coating
and cutting edge geometry are all specially designed
for each gear tooth material. As far as the actual machining
process is concerned, the material is irrelevant.
Chamfers can be milled into various steels, aluminium
and plastics within seconds.
Horn has developed a technology - together with the associated production process -
to enable defined chamfers to be milled
further information: www.phorn.de
18 no. 4, November 2020

materials & tools
Cost-effective even for small series
Tool system for milling bevel gear teeth
Horn’s new tool system for milling bevel gear
teeth allows the complete machining of bevel
gears on universal turn-mill centers. The system
was created in cooperation with machine manufacturer
INDEX and means that users no longer
need any special machines to manufacture gears
of this kind.
It also allows all functional surfaces to be produced together
with the gear teeth in one clamping. This enables
high component precision, short lead-times, a very cost-effi -
cient process and short machining times as a result of controlled
machining cycles. With a universal turn-mill center
from INDEX, components with bevel gear teeth can be
efficiently and flexibly manufactured, including in small
quantities. This also makes the process attractive to small
and medium-sized companies that would previously have
bought in gears or had them manufactured externally.
For the process, Horn relies on its S276 and S279 doubleedged
indexable inserts, which are screwed on tangentially.
This makes it possible to achieve a stable insert seat,
which is particularly important during form milling. The
tool does not have to be remeasured after the inserts have
been turned around or changed because the inserts are
precision-ground on the circumference. The milling body
can be equipped to allow for different numbers of teeth
and outer diameters when cutting gears.
The process of developing the complete system (cycle,
tool and clamping) calls for a great deal of expertise on
the part of both the machine manufacturer and the tool
manufacturer. To implement the process, various types of
INDEX machine with a “bevel gear hobbing” cycle are
re quired. Horn offers the milling cutter bodies with the
HSK-T40 and HSK-T63 interfaces. The profiles of the inserts
are module-dependent and precision-ground.
The new tool system for milling bevel gear
ensures high precision, short lead-times
and cost-effectiveness
For milling bevel gear teeth, Horn relies on its S276 and S279 double-edged
indexable inserts, which are screwed on tangentially
further information: www.phorn.de
no. 4, November 2020
19

materials & tools
Tiger•­tec ® pushes the boundaries
New coating grade for milling and drilling
With the new Tiger•­tec ® Gold PVD grade
WSP45G, Walter AG is introducing a cutting tool
material that really pushes the boundaries of
these coatings: both in their application and with
respect to the materials that the machinist can
work with them.
In addition to their compatibility with Xtra·tec ® XT, Walter
BLAXX and M4000 milling cutters, the new Tiger•­tec ® Gold
PVD indexable inserts can also be used in Walter indexable
insert drills such as the D4120; and that’s not only
for ISO P steels, but also for difficult-to-cut materials from
the ISO S and M material groups. The multilayer coating
system is the only one of its kind in the world: a TiAlN-
Al2O3 multilayer makes the WSP45G both hard and tough,
and therefore tremendously resistant to abrasive wear and
high temperatures. A special mechanical post-treatment
improves hairline crack performance and protects the cutting
edge from micro-spalling. The light gold-coloured top
coat of the multilayer system makes it easier to detect wear
and thereby improves process reliability. Unused cutting
edges are reliably identified, making it possible to exhaust
the full potential of the indexable insert.
Potential fields of application for the new Tiger•­tec ® Gold
PVD grade include demanding machining tasks, like materials
with difficult cutting properties, tricky conditions or
interrupted cuts. In the case of milling, these challenges
could also be long overhangs or delicate clamping arrangements;
with drilling, inclined entries and exits. Depending
on the material and application, the new Tiger•­tec ® Gold
PVD grade achieves performance improvements of up to
75 %. For turbochargers in cast steel, fasteners and chassis
parts in titanium or components in nickel-based alloys as
encountered in the automotive, energy and aerospace industries,
the WSP45G grade is an ideal problem solver.
The new Walter Ti­ger•­tec ® Gold PVD grade WSP45G
further information: www.walter-tools.com
20 no. 4, November 2020

materials & tools
Precision diamond profile dressing rolls
“HiTech rotary-dress”
In this year, with almost no trade shows, it is difficult
to introduce product developments.
PROCESS TECHNOLOGY & COMPONENTS
“HiTech rotary-dress” diamond dressing rolls from LACH
DIAMANT, diamond tool manufacturer in Hanau since 1922, automate
dressing processes in serial production while optimizing the
use of machine capacity.
“rotary-dress” diamond dressing roles feature highest repetition accuracy at
lowest dressing costs. Recommended for high-precision components such as
bearing tracks, valves, gear wheels, turbine blades or turbochargers.
© SEEPEX
Example of bearing industry: bearing tracks of high-precision bearings (inner rings)
Precision diamond dressing rolls “HiTech rotary-dress” are manufactured
in the following versions, depending on the machining task:
sintered, negative
electroplated, negative
electroplated, positive
‣ set or handset diamond coating
‣ CVD edge reinforcement
‣ randomset or handset diamond coating
‣ CVD edge reinforcement
‣ randomset diamond coating
‣ CVD edge reinforcement
The cross-sectoral media platform
for suppliers and users in two languages:
German and English
Exclusive information around the pump
and compressor industry as well as
systems and components
Developments and trends
First-hand future technology
Profile diamond dressing roll with
CVD edge reinforcement
Targeted at international trade shows
for 2020
Special issue for the Russian market
in October
further information: www.lach-diamant.de
Dr. Harnisch Verlags GmbH · Eschenstr. 25
90441 Nuremberg · Tel.: +49 (0) 911 - 2018 0
info@harnisch.com · www.harnisch.com

materials & tools
LACH DIAMANT looks back on 98 years - 6 th part
Poly - poly - or what?
Quo vadis - Where are you going… ?
Horst Lach, managing director
and CEO of LACH DIAMANT,
agreed to write an ongoing series
of articles about the development
of diamond and CBN tools
and grinding wheels in modern
industries.
Horst Lach is known as a true
industry veteran, and we are
ex cited to have this pioneer of
tech nology share some insights
from his 59 years of professional
experience in the diamond tool
business.
In the sixth part of this (almost)
historical review, Horst Lach recalls
the time when PCD tools
became accepted in the wood
manufacturing industry.
At the time of LIGNA 1979, the inter -
national trade show for machines and
equipment for the wood industry,
polycrystalline diamonds had on ly
been available to the tool industry for
six years - and polycrystalline boron
nitride cutting edges only for five
years - both from the manufacturer
General Electric Superabrasives. The
dia meter of a PCD blank was max.
13.2 mm (see figure 1).
No good business (yet)
At that time, the production of polycrystalline
cutting edges might not
have been good business for the
manu facturer (yet). Generally, this
was related to the total sales success of
General Electric Superabrasives, with
a manufacturing site in Worthington/
Ohio, USA, and within GE’s corporate
organization subordinate to the GE
bulb manufacturer. A subsequent conversation
with General Manager Louis
Kapernaros indirectly confirmed this.
In fact, up to LIGNA 1979, polycrystalline
cutting materials were, with
few exceptions, only used for mounting
so-called indexable inserts (see article
“Poly - poly -or what?”, part 5)
During the introduction of PCD
tools, the automobile industry only
played a minor part at first. Two major
events had to create the basis for
today’s essential role of these tools
for serial production. The oil crises of
1973 and 1979/80 - initiated by wars
in the Near East and consciously reduced
oil outputs - demonstrated to
the world our dependence on this
type of energy. Many of us can still
remember obligatory fuel saving
measures, weekend driving bans and
the inevitable petrol coupons when
taking a trip abroad.
The fact that polycrystalline diamonds
(PCD) could “show profile”
(also see 4 th and 5 th part of “Poly - poly
- or what?”) in October 1978 - now 42
years ago - could be attributed to random
chance, but could it have something
to do with “luck”? But how did
golf professional Tiger Woods answer
when a journalist pointed out that
he often had a lot of luck during his
games? “The more I train, the more
luck I have…”
In my - our - case this is indeed true.
Training is possible. To listen carefully,
process everything, and come
back to it at the right moment, and
put it all together at the appropriate
moment.
More or less like when my father
Jakob Lach told me that electricity
played a role in grinding natural diamonds.
This remark alone sparked
a thought while reading an advertisement
for spark erosion machines
by the former company Matra; it led
to the discovery of spark erosion for
forming polycrystalline diamonds.
And now to “Poly - poly - or what?” -
Quo vadis - where are you going?
figure 1
Available PCD blanks and templates by GE Superabrasives as of 1979/80
22 no. 4, November 2020

materials & tools
figure 2
The world’s first presentation of diamond tools for plastic machining at LIGNA 1979
in Hanover
For the first time the wish for new energies came up -
even climate protection was not excluded from the discussions.
Petrol guzzling motors were critically examined.
Motors were to become smaller and yet more efficient,
and for the first time weight reduction became an issue
for the entire automobile industry. Robots were already
known to be used in serial production in Japan. Robots are
fine, as long as they fit into the “work environment”, but
with what kind of long-term tools? And especially during
machining of promising, weight-reducing aluminium
components? You already know - the decision had to be
in favour of polycrystalline diamonds.
A little anecdote regarding the now following wave of
requests for alumi nium machining tools from the automobile
industry. Since there were no numbers regarding
the tool life of PCD tools in the serial production of aluminium
components at the end of the 70 s , standard consumption
data for carbide tools were
used as orientation. Therefore, the demand
specifications were based on very
high PCD quantities.
However, the initial enthusiasm of
PCD manufacturers receiving these
requests and orders quieted down -
since the quantities had to be drastically
reduced after a few months. The tool
life of the cutting edges of PCD tools
surpassed that of carbide cutting edges
by up to several-hundred fold.
“Has Lach lost it?”
Back to LIGNA 1979. LACH-SPEZIAL-
WERKZEUGE GmbH had only been
founded in February (see “Poly - poly -
or what?”, part 5). It was preparing to be
the world’s first company to introduce
a complete diamond tool and saw program
for the wood and plastic industry.
Of course from the very start the LACH
specialists faced the question, how the
audience, the industry, would react to this world premiere:
“Diamonds for wood and plastic? Has Lach lost it now?”
These were indeed some of the comments during LIGNA
where we featured the entire diamond tool program at a
large stand, accessible from three sides (see figure 2 and 3).
In the meantime, LACH-SPEZIAL diamond tools were already
used by selected customers of the wood and plastic
industry, e. g. Resopal (see article “Poly - poly - or what?”, part
5) and Messerschmitt-Bölkow-Blohm GmbH in Donauwörth
and Augsburg. This was the beginning of a suc cessful
collaboration. The trade press, provided with information
about the eco nomically efficient, cost-reducing use
of diamond tools for machining wood and plastic, witnessed
with their own eyes the at first cautious and then
enthusiastic activities at the LACH-SPEZIAL stand. In
short, it was all in all a very successful introduction of a
new technology.
figure 3
Another way how diamond tools for wood and plastic machining were presented at LIGNA 1979
no. 4, November 2020
23

materials & tools
figure 4 and 5
LIGNA 1979 - LACH already presents the entire diamond tool programme
for machining wood and plastic materials and far superior to carbides -
in this example saws and pre-scoring devices
Employees of GE Superabrasives who visited the LACH-
SPEZIAL stand, were able to gladly report back to the USA
that now more PCD than before could be sold. This was
also thanks to the discovery of spark erosion which initially
made the commercial production of polycrystalline
milling tools possible. Now they could focus on the
production of higher quantities, and where appropriate
even invest in larger diamond presses. To date, we had to
use PCD blanks with 13.2 mm diameter and stack them
accordingly to the width of the milling cutter.
In any case, for GE these news must have been pointing
the way into the future. Consequently, the blanks supplied
became larger in diameter - e. g.
from 13.4 mm and 30 - 52 mm up to
58 mm today!
Not to mention that in time for
LIGNA, an “old” supplier of natural
diamonds, DeBeers, promoted and
called attention to a synthetic PCD
product named Syndite.
PCD on the tool
Eventually, even traditional wood
tool manufacturers had to deal with
the “newcomer” LACH-SPEZIAL
who did not only have diamonds in
its “kit” but also PCD on the tools.
Milling tools, scorers, hoggers, saws
etc., and these tools were supposed
to have a tool life up to 250 times
longer than that of carbide tools (see
figures 4 and 5).
At this point, this was understandably
an uncomfortable situation for
manufacturers of carbide tools for wood machining; carbide
tools had been very successful, thanks to synthetic,
metal-coated diamonds and grinding machine developments
for wood machining tools as the key elements. And
now diamond - as superior cutting edge material compared
to carbide? Start all over again?
In retrospect, it was not easy at times to face the arguments
of competitors. LACH-SPEZIAL quickly realized that
these long-lasting diamond tools needed a stable, compact
seating, and securely soldered the PCD to the steel base.
This was an opportunity to warn potential users of dangers
to life and limb - also for the machine - due to detaching,
chipping diamonds.
This might also have been the reason
that all shown diamond tools
on double end tenoners in the
LACH-SPEZIAL video (www.vimeo.
com/206233393 and www.vimeo.
com/206231829) were all mounted
on older machines (see figure 6).
figure 6
Adjustable diamond tool on an “older” machine
To guard against such arguments
which would impede the market
introduction, LACH-SPEZIAL
had a profile milling cutter
180 x 15 x 30, R = 6.5, polycrystalline
diamond as cutting material,
Z = 2 + 2 (soldered) examined by the
testing center of the occupational
association for wood machining
tools. The test certificate BG-Form
#81016 is still available today. This
also applies to the examination
according to BG-Test (ZU-8701);
(see figures 7 and 8).
24 no. 4, November 2020

materials & tools
figure 7 and 8
After examination, a diamond profil milling cutter was marked
“BG-Form” back then - today “BG-Test”
After first end milling cutters with straight cutting edges
appeared officially or unofficially among competitors at
LIGNA 1981, even customers who had been hesitant to use
LACH-SPEZIAL diamond tools now said: “Now LACH is
right after all. We can now go directly to diamond specialist
LACH-SPEZIAL…” and that’s what happened.
Further pioneering achievements
The trade press (see press review 1979-80-81 on www.lachdiamant.de)
had already formed their opinion. “Oberfläche
+ Jot” reported already in September 1979: “Diamonds
machining wood and plastic - the introduction of LACH-
SPEZIAL programs at LIGNA ’79 was for wood and plastic
machining like a view into the future that had just begun.
The featured dreboform ® diamond profile milling cutters
do not only mill wood and plastic with the same precision
as previously used carbide tools - dreboform ® diamond
profile milling cutters surpass the tool lives of
carbide tools by several hundred fold.
experiences. The 5 th and 6 th part
of this historical review was
dedi cated to the first few
months of the presentation and
introduction of diamond tools
in the furniture and wood and
plastic industry in regard to
LIGNA 1979.
On the agenda
for the future
The demonstrated use of PCD
as a superior cutting edge material
for wood and plastic
machining was only the mere
beginning of their future
potential (see figure 9).
These results soon led to the
implementation of polycrystalline
diamonds in the automobile
and aviation industry,
and later even to the adoption
in the wind energy industry -
just to hint at a few future topics.
You might also be curious
to know how diamond tools
changed the furniture, parquet
and composite industries, especially in Europe and
USA, to the present day - even the milling of conventional
grinding wheels will become a topic among possibly many
others.
The author will show the further development of polycrystalline
diamonds from his own experience. True to the
title of this sequence “Quo vadis - where are you going?”.
Horst Lach
One can easily imagine what this meant for serial production
alone, e. g. kitchen and office furniture, where
tool changes rendered machines unproductive for up
to two hours. Another trade publication, “Holz – Die
Österreichische Möbelzeitschrift 8/79”, reported: “A technical
sensation from America is now also offered for wood
machining: tool cutting edges made from polycrystalline
synthetic diamonds. It will be shown whether these new
tools are efficient for wood machining and how the new
diamond tools will be applied in the future.”
As reader of the article series “Poly - poly - or what?”, by
now you already know better; not to mention your own
figure 9
A view into the future of machining aluminium in the
automobile industry - diamond monoblock cutter Z = 16
with cool injection and chip breaker
further information: www.lach-diamant.de
no. 4, November 2020
25

news & facts
companies
Restructuring plan approved
KOMET Deutschland GmbH has adopted a
restructuring plan aimed at a rapid return to profitability.
It includes the closure of the Stuttgart-
Vaihingen site by the end of 2021 at the latest. In
future, the CERATIZIT Group will cover the competencies
located there with the sites in Besigheim
and Kędzierzyn-Koźle.
At its meeting on June 30 th , the Supervisory Board of
KOMET Deutschland GmbH approved a restructuring plan
submitted by the Management Board, which will bring the
precision tool manufacturer back to profitability. As part
of these measures, the KOMET site in Stuttgart-Vaihingen
will be closed by the end of 2021 at the latest. Thus,
KOMET is following the CERATIZIT Group’s global strategy,
as Executive Board Speaker Andreas Lackner explains: “The
Covid-19 pandemic has further increased cost pressure in
the tool industry. To remain competitive in this market
environment, we will continue to concentrate our production
capacities and accelerate the focusing of individual
production sites on specific product families.”
Restructuring of the production network
Central areas of production at the Stuttgart-Vaihingen
site, such as the finishing of PCD tools (polycrystalline
dia mond) and 3D printing with metal, but also design
and development, will be covered by the KOMET site in
Besigheim. Other areas will be covered by the CERATIZIT
site in Kędzierzyn-Koźle, Poland. For the Besigheim site,
this restructuring project means a further strengthening
of competencies in the production of PCD tools.
further information: www.ceratizit.com
New management at Supfina -
the solution provider
On October 1, 2020, Christoph Siegel, a graduate
in business administration, took up his position
as managing director of Supfina. With his professional
expertise in international mechanical engineering
and business administration, he will drive
the successful orientation of the Black Forest company
as a provider of high-tech solutions for automated
manufacturing systems.
After completing his studies, he has worked for different
companies including Schaeffler Group, ARKU Maschinenbau,
Sortimo International and LIEBHERR in both Germany and
internationally. “Our goal is to optimize the advantages
of our customers and to contribute our experience in the
identification of solutions at an early stage. The entire
Supfina team is ready to support this”, Mr. Siegel said in a
first statement.
With locations in Germany, the USA and China, Supfina
Grieshaber is one of the world’s leading suppliers of
modern solutions for the fields of mechanical and industrial
engineering, automation, robotics and services. The
company employs more than 200 qualified and highly
specialized employees. Based on decades of experience,
the modern company offers integrated and innovative
systems - including comprehensive services.
further information: www.supfina.com
Christoph Siegel,
new managing director of Supfina
26 no. 4, November 2020

companies
news & facts
New general manager
of sales and marketing
at SW machines
300% faster programming
of complex tools
with new Rollomatic’s Machining Software
on the LaserSmart ® 510
After two decades, Reiner Fries has decided
to retire from his role as General Manager
of Sales and Marketing at SW as well as his
other SW-Group functions. His successor, Jörg
Schmauder will bring his over 13 years of
management experience in the machine tool
industry. The handover is slated to take place
by the end of the year.
SW is a leading machine, automation and system
solutions supplier, headquartered in Waldmössingen,
Germany. The company has multiple worldwide subsidiaries
with locations in the US, Mexico and Asia,
as well as in several European countries.
Mr. Schmauder will work alongside Markus Schmolz
(CFO) and Stefan Weber (CTO), who will be remaining
in their roles as Managing Directors leading the
SW-Group worldwide. While the official handover is
set to happen this December, Mr. Schmauder has been
at SW since the first of July, working with Mr. Fries.
This overlap is part of SW’s approach toward ensuring
a smooth transition.
SW is looking forward to this new chapter and continues
to strengthen a leading position as a manu -
facturing sys tems supplier, both in North America
and worldwide.
further information: www.sw-machines.de
from the left:
Markus Schmolz (CFO, SW), Jörg Schmauder (new CSO, SW),
Stefan Weber (Geschäftsführer CTO, SW)
www.rollomaticsa.com

news & facts
IFR presents World Robotics 2020
Record 2.7 million robots work in factories
around the globe
The new World Robotics 2020 Industrial Robots
report presented by the International Federation
of Robotics (IFR) shows a record of 2.7 million industrial
robots operating in factories around the
world - an increase of 12 %. Sales of new robots
remain on a high level with 373,000 units shipped
globally in 2019. This is 12 % less compared to
2018, but still the 3 rd highest sales volume ever
recorded.
“The stock of industrial robots operating in factories
around the world today marks the highest level in history,”
says Milton Guerry, President of the International Federation
of Robotics. “Driven by the success story of smart
production and automation this is a worldwide increase
of about 85 % within five years (2014 - 2019). The recent
slowdown in sales by 12 % reflects the difficult times the
two main customer industries, automotive and electrical/
electronics, have experienced.”
“In addition to that, the consequences from the coronavirus
pandemic for the global economy cannot be fully
assessed yet,” proceeds Milton Guerry. “The remaining
months of 2020 will be shaped by adaption to the ‘new
normal’. Robot suppliers adjust to the demand for new
applications and developing solutions. A major stimulus
from large-scale orders is unlikely this year. China might
be an exception, because the coronavirus was first identified
in the Chinese city of Wuhan in December 2019
and the country already started its recovery in the second
quarter. Other economies report to be at the turning
point right now. But it will take a few months until this
translates into automation projects and robot demand.
2021 will see recovery, but it may take until 2022 or 2023
to reach the pre-crisis level.”
Asia, Europe and the Americas - overview
Asia remains the strongest market for industrial robots -
operational stock for the region’s largest adopter China rose
The International Federation of Robotics
is the voice of the global robotics industry.
IFR represents national robot associations,
academia, and manufacturers of industrial robot
manufacturers from over twenty countries. IFR
was founded in 1987 as a non-profit organization
by 21 % and reached about 783,000 units in 2019. Japan
ranks second with about 355,000 units - plus 12 %. A runner-up
is India with a new record of about 26,300 units -
plus 15 %. Within five years, India has doubled the number
of industrial robots operating in the country’s factories.
The share of newly installed robots in Asia was about
two thirds of global supply. Sales of almost 140,500 new
robots in China is below the record years of 2018 and 2017
but still more than double the numbers sold five years
ago (2014: 57,000 units). Installations of top Asian markets
slowed down - in China (- 9 %) and Japan (- 10 %).
“In China, the broad majority of 71 % of new robots
was shipped in from foreign suppliers. Chinese manufacturers
still mainly cater to the domestic market, where
they gain increasing market shares. Foreign suppliers deliver
some 29 % of their units to the automotive industry,
while it is only around 12 % for Chinese suppliers. Therefore,
foreign suppliers are more affected by the decline
of business in the Chinese automotive industry than the
domestic suppliers.
Europe
Europe reached an operational stock of 580,000 units in
2019 - + 7 %. Germany remains the main user with an
operational stock of about 221,500 units - this is about
three times the stock of Italy (74,400 units), five times the
stock of France (42,000 units) and about ten times the
stock of the UK (21,700 units).
Robot sales show a differentiated picture for the largest
markets within the European Union: about 20,500 robots
28 no. 4, November 2020

news & facts
with almost 15,300 units - plus 8 %. Sales
slowed down by 17 % with about 1,800 installations
- still one of the best results ever -
only beaten by record shipments in 2018.
Worldwide trend in human-robot
collaboration
The adoption of human-robot collaboration is
on the rise. We saw cobot installations grow
by 11 %. This dynamic sales performance was
in contrast to the overall trend with traditional
industrial robots in 2019. As more and
more suppliers offer collaborative robots and
the range of applications becomes bigger, the
market share reached 4.8 % of the total of
373,000 industrial robots installed in 2019.
Although this market is growing rapidly, it is
still in its infancy.
were installed in Germany. This is below the record year
2018 (- 23 %) but on the same level as 2014 - 2016. Sales
in France (+ 15 %), Italy (+ 13 %) and the Netherlands
(+ 8 %) went up. Robotics in the United Kingdom remains
on a low level - new installations slowed down by 16 %.
The newly installed 2,000 units in the UK are about ten
times less than the shipments in Germany (20,500 units),
about five times less than in Italy (11,100 units) and about
three times less than in France (6,700 units).
Americas
The USA is the largest industrial robot user in the Americas,
reaching a new operational stock record of about 293,200
units - up 7 %. Mexico comes second with 40,300 units,
which is a plus of 11 % followed by Canada with about
28,600 units - plus 2 %.
Outlook
Globally, COVID-19 has a strong impact on 2020 - but
also offers a chance for modernization and digitalization
of production on the way to recovery. In the long run,
the benefits of increasing robot installations remain the
same: rapid production and delivery of customized products
at competitive prices are the main incentives. Automation
enables manufacturers to keep production in developed
economies - or reshore it - without sacrificing cost
efficiency. The range of industrial robots continues to expand
- from traditional caged robots capable of hand ling
all payloads quickly and precisely to new collaborative
robots that work safely alongside humans, fully inte grated
into workbenches.
further information: www.ifr.org
New installations in the
United States slowed down
by 17 % in 2019 compared to
the record year of 2018. Although,
with 33,300 shipped
units, sales remain on a very
high level representing the
second strongest result of all
time. Most of the robots in
the USA are imported from
Japan and Europe. Although,
there are not many North
American robot manufacturers,
there are numerous important
robot system integrators.
Mexico ranks second in
North America with almost
4,600 units - a slowdown of
20 %. Sales in Canada are 1 %
up to a new record of about
3,600 shipped units.
South America’s num ber one
operational stock is in Brazil
no. 4, November 2020
29

news & facts
fairs
DeburringEXPO 2021
International meeting place for
deburring technologies and precision surface finishing
Markets, supply chains,
manufacturing technologies
and processes are changing.
Entire sectors are realigning
themselves. This transforma -
tion is making it more and
more important for companies
to demonstrate presence,
and to function as solution
providers. Where deburring
and the production
of precision surface finishes
are concerned, there’s no get -
ting round DeburringEXPO.
The 4 th leading trade fair for deburring
technology and preci sion
surface finishing will be held
at the Karlsruhe Exhibition Center
October 2021, from the 12 th to
the 14 th . The exhibition portfolio
covers the processing of components
manufactured by means
of all technologies, and from all
industry sectors. The expert forum,
which is in great demand
as a source of knowledge, rounds
out the exhibition programme
with highly practical, simultaneously
interpreted presentations.
Taking advantage of the
right setting
“The challenges faced by companies
from virtually all manufacturing
industries also have an
impact on surface finishing processes
such as deburring, rounding,
the production of precision
surfaces and cleaning. Beyond this,
these process steps are becoming
more and more important
in the growing market for component
conditioning,” explains
Hartmut Herdin, managing director
of trade fair promoters
fairXperts GmbH & Co. KG. Key requirements
in this regard include
ongoing quality improvement,
increased efficiency, optimisation,
automation and the digitalisation
of processes, as well as
The exhibitors at DeburringEXPO offer solutions for efficiently and reliably
fulfilling the requirements of changing markets and industries
solutions for parts and components manufactured using new and modified production
technologies, for example additively manufactured workpieces and work
pieces made of hybrid materials.
As a specialised trade fair, DeburringEXPO portrays these issues precisely, offers
a complete overview of current and new solutions and showcases current trends in
the various industry sectors. Its clear focus makes the leading trade fair for deburring
technologies and precision surface finishing an ideal setting for presenting
corresponding solutions, as well as for establishing and expanding networks and
detecting upcoming technologies at an early stage. Prominent companies from the
industry sector, including numerous market and technology leaders, see things in
the same way and have already made firm bookings for their trade fair booths
more than a year before the event opens.
Increased focus on automation and cleaning
The supplementary programme at DeburringEXPO, October 2021, from the 12 th
to the 14 th , will be geared to increasing demands for efficiency in production and
changing manufacturing technologies, for example in the areas of joining, coating
and assembly. The new theme park for “Automated Deburring with Industrial
Robots” will provide information concerning corresponding solutions, and
will also address the integration of deburring and rounding processes in an interlinked/digitalised
production environment. The “Cleaning After Deburring”
theme park deals with growing demands for technical cleanliness.
further information: www.deburring-expo.de
30 no. 4, November 2020

fairs
news & facts
Flagship Technology ESPRIT CAM at IMTS Spark
Attendees at the virtual
IMTS Spark show can watch
videos, download informational
material, and interact
with representatives from
DP Technology, makers of
the ESPRIT CAM system.
The International Manufacturing Technology Show, or IMTS,
is one of the manufacturing industry’s most anticipated
events. In response to the COVID crisis, the 2020 IMTS
event is IMTS Spark, a fully virtual showcase of leaders in
manufacturing technology. The event runs from August
25, 2020 until March 15, 2021.
IMTS Spark attendees can interact with the ESPRIT
product, a full-spectrum CAM system that supports the
entire manufacturing process. At the ESPRIT virtual showroom,
Spark attendees can watch live, 15-minute video
demonstrations of ESPRIT. One new demonstration will
be produced each month, beginning on September 22
and continuing through February
2021. Additionally, attendees
can also access product highlight
videos and new case studies
that showcase ESPRIT’s practical
applications and highlight users
from various industries. Finally,
a live chat with ESPRIT engineers
will be available, allowing attendees to receive focused attention
even while remote.
The ESPRIT virtual showroom also features a library of
downloadable informational material so attendees can
learn even more about ESPRIT’s latest product highlights.
“IMTS is such a great opportunity to get face time with
other members of the manufacturing industry,” says Don
Davies, executive vice president of North America sales
at DP Technology. “Like most events, IMTS is different
in 2020, but we’ve adapted. We’re still looking forward
to connecting with customers, potential users, and peers
from all over the world.”
further information: www.dptechnology.com
With more than a century’s
worth of experience, we find
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Discover our innovative grinding tools for highprecision
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Premium grinding tools since 1919
www.tyrolit.com

processes
Oxygen-free production:
New manufacturing approach in grinding
written by Prof. Dr.-Ing. Berend Denkena, Dr.-Ing. Alexander Krödel and M. Sc. Nils Hansen,
authors from the Institute of Production Engineering and Machine Tools IFW
Production engineering is constantly driven
by increasing demands regarding economically
efficient manufacturing processes as well
as increasing requirements on the precision of
machined workpieces. With respect to precision
machining, surface quality plays a key role in
evaluating machined surfaces. Because of its ability
to enable high surface qualities, grinding is
the most commonly used finishing process [1, 2].
However, grinding of materials that are difficult
to machine, like titanium (Ti), can lead to rapid
tool wear and therefore high process costs [3].
Since titanium is of great importance to the industry
as a material for applications in lightweight
construction (e. g. aerospace), there is a big market
for machined titanium parts. Conse quently, there
is a considerable interest in optimizing existing
production processes. In a new approach, an oxygen-free
atmosphere will be used within manufacturing
processes, which could potentially lead to
longer tool life and higher workpiece qualities.
Due to the presence of oxygen in usual machining processes,
metal workpiece surfaces tend to oxidize at elevated
temperatures, which can lead to an increased hardening
and embrittlement in the subsurface microstructure. Especially
when it comes to machining materials like titanium
that possess a high chemical affinity to oxygen, oxidation
effects are distinct [4]. This results in higher tool wear and
also poor surface qualities of the workpiece [3]. Based on
this premise an entirely new approach will be investigated
within the “Collaborative Research Centre: Oxygen-free
production” over the next years to improve manufacturing
processes like grinding. For this purpose, an oxygenfree
atmosphere within the grinding process will be used
to eliminate oxidation effects and therefore increase the
life of grinding tools. Another aspect of the research project
is the sintering of metal bonded grinding tools under
an oxygen-free atmosphere. Oxygen within the sintering
process also leads to oxidation of powder particles, which
potentially has a negative influence on the strength of the
abrasive layer as well as the retention of diamond abrasive
grains. This article will present results that were gained in
first experiments.
A new approach to the process chain
of grinding tools
To investigate the influence of the oxygen-free manufacturing
of grinding tools and the behavior of those tools in
grinding processes the gas mixture of argon/silane (Ar/SiH 4
)
is used in sintering and grinding experiments. Oxygen
can be displaced by a heavier and chemically inert gas like
argon (Ar). Since argon is not able to displace oxygen entirely
low contents of monosilane (SiH 4
) can be doped in
argon to further reduce the residual content of oxygen.
The reaction of silane with oxygen results in the formation
of water and a silicon dioxide powder [5]. At ambient pressure,
this reaction generates an atmosphere with very low
oxygen partial pressures (≤ 10 -23 bar). With respect to the
oxygen content, the resulting atmosphere is adequate to
an extremely high vacuum (XHV). Compared to this approach
generating a conventional technical ultrahigh vacuum
(UHV) is much more expensive and complex and can
only enable oxygen partial pressures down to 10 -15 bar.
For sintering and grinding experiments, a mixture of
98.5 Vol.-% argon and 1.5 Vol.-% silane is used. The associated
process chain consists of four steps whereas the
sintering step is divided into “grinding tools” and “specimens”
(figure 1). Grinding wheels are sintered and conditioned
to carry out grinding experiments to evaluate
their behavior (e. g. tool wear). The results can then be
correlated to the sintering parameters in order to individually
adapt the grinding tool manufacturing process to the
grinding application [6]. Specimens on the other hand are
sintered at similar conditions and are used for scientific
characterizations of abrasive layers. This enables to investigate
a large variety of abrasive layer compositions and
different process parameters. In addition, compared to
the sintering of entire grinding wheels specimens can be
produced at much lower production costs [6 - 10].
32 no. 4, November 2020

processes
figure 1, process chain of grinding tools and specimens
Potential of oxygen-free atmosphere
in sintering of abrasive layers
All sintering experiments are carried out on a sintering
press DSP 510 from Dr. Fritsch. The specimens are sintered
in a graphite mold with graphite dies (figure 2, top left) at
given constant process parameters in a resistance heating
process. The sintering process is performed under air
with ambient pressure and under a silane doped inert gas
atmosphere (Ar/SiH 4
) with low oxygen partial pressure.
The bond material consists of 100 % titanium that tends
to form carbides when using diamond as abrasive grain.
In order to eliminate additional chemical reactions of the
Ti-powder with the grain during sintering, no abrasive
has been used in these first tests. In doing so the results of
the investigation only base on the bond material and can
therefore be evaluated separately.
After this, a three-point flexural test can be conducted to
determine the force F Z
at which the specimens break. This
enables to calculate the critical bond stress σ by taking
the diameter d, height h and support length l of the specimens
into account (figure 2, center left); [6]. The calculation
assumes an area moment of inertia of I y
= (d * h 3 )/12. The
critical bond stress is a characteristic value that describes
the ability of the specimen to withstand mechanical loads.
It can also be used to compare specimens that are sintered
under different conditions. Previous studies have shown
that a higher bond stress results in a decreased wear of the
grinding tools [7].
The ambient atmosphere has a significant influence on
the resulting bond stresses of sintered Ti-specimens (figure 2,
center). The bond stress of specimens sintered under
Ar/SiH 4
(335 N/mm 2 ) is over five times the amount of
the specimen bond stress that results at sintering under
air (65 N/mm 2 ). The main reason for this result is the influence
of oxygen within the process. Since oxygen is
not able to diffuse out of the titanium powder during
sintering because of ambient pressure conditions the reaction
of titanium particles with oxygen is distinct. The
forming of titanium oxides intensifies with increasing
temperatures during sintering, which leads to a less homogeneous
microstructure [11]. In the case of the Ar/SiH 4
atmosphere, a significantly lower content of oxygen is
present that enables much higher critical bond stresses.
Due to the reduction of oxidation effects titanium can
now form a more homogeneous microstructure that is
able to withstand higher mechanical loads.
A visual analysis of the specimen cross-sections after the
fractural test shows a noticeable difference between the
surfaces. Specimens that are sintered under air have blue
and brown colored areas (figure 2, right). The distinct coloration
is a result of the oxidation of titanium during sintering
and can consist of various titanium oxides (e. g. TiO 2
,
TiO) [12]. The color gradient indicates different oxide types
as well as different Ti-oxide layer thicknesses [13]. These
visual observations confirm the forming of titanium
oxides that lead to a decreasing material strength. When
sintering under Ar/SiH 4
atmosphere no oxide layers can
be visually found on the cross-section surface of the specimens.
This can be explained by the low oxygen partial
pressure that prevents the oxidation of titanium, which
results in higher bond stresses.
Later investigations will also include the use of diamond
and cBN grains to explore the influence of the atmosphere
on the interface between bond and abrasive grains. The
temperature-dependent oxidation behavior of titanium
could potentially prevent the forming of carbides and thus
the chemical retention of the grain [4, 11]. By using an Ar/
SiH 4
atmosphere oxidation effects will be reduced, which
could lead to higher grain retention forces and would
therefore increase the critical bond stresses.
no. 4, November 2020
33

processes
figure 2, left: mechanical characterization of specimens; right: cross-section analysis of specimens
Oxygen-free atmosphere as enabler
to reduce tool wear
Further experiments are performed to determine the influence
of the oxygen-free environment on the result of the
grinding process. For this investigation, a bronze-bonded
grinding wheel with diamond grain is used to machine
titanium (Ti6Al4V) under air and Ar/SiH 4
atmosphere. For
the latter, the face grinding process is conducted within
a gastight housing to ensure low oxygen partial pressures
(figure 3, center). For grinding under air, the housing is
removed to enable normal grinding conditions. An EDXanalysis
is performed afterward which enables to determine
the elemental composition of the material by measuring
the characteristic X-rays. The results of the EDXanalysis
of the machined workpiece surfaces show that the
atmosphere has an impact on the oxygen content of the
workpiece material. The atomic percentage of oxygen decreases
by 60 % comparing the results of grinding under
air and Ar/SiH 4
(figure 3, right). The main reason for this
outcome is the low content of residual oxygen within the
figure 3, left: experimental setup for grinding under air and Ar/SiH 4
atmosphere; right: results of EDX-analysis
34 no. 4, November 2020

processes
process under Ar/SiH 4
, which leads to lower gas diffusion
into titanium and consequently less pronounced oxidation
effects in the subsurface microstructure. The residual
oxygen content of 6.8 atom.-% can partially be explained
by the period of time between the grinding process and
the EDX-analysis in which a thin oxide layer has formed
due to the natural reaction of titanium with oxygen. This
result is confirmed by additional tests in which a recently
ground Ti-surface (oxygen content < 1 atom.-%) and an unmachined
Ti-surface (oxygen content ≈ 10 atom.-%) were
examined. The time between the grinding process and the
analysis was approximately 15 minutes. These explanations
can also be applied to the visual observation of the
grinding process and the result of the surface quality of
the Ti-workpiece, which is described below.
This can mainly be attributed to oxidation effects during
grinding. The resulting surface colors are comparable
to those on the sintering specimens and can also be
attributed to different oxide types as well as different
oxide layer thicknesses [13]. Although the effect of
Ti-oxidation at elevated temperatures also thermally
damages the surface, it cannot be entirely equated
with grinding burning since the latter does not include
damage caused by chemical reactions like oxidation
[14, 15].
The formation of oxidation on the surface can be
compared to the anodizing process anodic spark deposition.
The material is heated locally in the contact
area and stays molten for a short period of time.
This leads to a strong reaction of titanium with oxygen
[16]. In contrast to the anodizing process in which
a chemical reaction is wanted to create a wear-resistant
passive layer, oxidations on the workpiece during
grinding should be avoided. The reason for this is that
oxide layers cause a hardening of the original surface,
which in turn leads to an increase of grinding forces
and tool wear [3, 4].
Conclusion and outlook
The results of the experiments show that oxygen has
a significant impact on the processes sintering and
grinding. On the one hand, oxygen causes a weakening
of the abrasive layers due to oxidations that results
in inhomogeneous structures. On the other hand,
oxygen within the grinding process leads to surface
oxidation and thus to possibly higher tool wear compared
to grinding under Ar/SiH 4
atmosphere.
figure 4, microscope images of ground Ti-surfaces
Due to the experimental setup, no cooling lubricant can
be used within the gastight housing. This leads to higher
friction and temperatures in the contact area between tool
and workpiece. While strong sparking can be observed
when grinding in the presence of air, this effect is much
less pronounced under Ar/SiH 4
atmosphere. This confirms
the significantly lower content of oxygen in Ar/SiH 4
atmosphere
since the exothermal reaction of removed titanium
chips with oxygen is less distinctive. However, due to
minor leakages in the current setup small quantities of
oxygen are still present within the process.
The visual results of titanium workpieces show that
the machined surfaces are less affected by chemical reactions
when ground under Ar/SiH 4
atmosphere (figure 4).
Based on the presented results further scientific
investigations will be conducted to gain a deeper
understanding of the processes and mechanisms.
This includes sintering experiments under different
atmospheres and various abrasive layer material
compositions as well as different grinding tests to
determine the influence on grinding tools and workpieces.
To investigate, for example, the material
removal mechanisms during grinding a quick stop
device will be used. It enables the interruption of cut
so that the contact zone on the workpiece surface
can be seen as a snapshot of the current chip formation
mechanisms.
Furthermore, an improved gastight housing will be
developed to allow the feed of cooling lubricant into
the contact zone between tool and workpiece. A measurement
module will also be applied to measure the
exact amount of residual oxygen content within the
housing and especially near the contact zone.
Acknowledgements
The authors would like to thank the German Research
Foundation (DFG) for their organizational and financial
support within the “Collaborative Research Centre
1368: Oxygen-free production” and the subproject
“Cooling concepts for Grinding” in particular.
no. 4, November 2020
35

processes
Prof. Dr.-Ing.
Berend Denkena
Dr.-Ing.
Alexander Krödel
M. Sc.
Nils Hansen
Literature
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Grinding technology:
Theory and applications of machining with abrasives
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Fertigungsverfahren 2: Schleifen, Honen, Läppen
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3. Teicher, U.; Künanz, K.; Ghosh, A.; Chattopadhyay, A.B.:
Performance of Diamond and CBN Single-Layered
Grinding Wheels in Grinding Titanium
Materials and Manufacturing Processes 2008, 23(3),
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Titan und Titanlegierungen
Springer Berlin Heidelberg: Berlin, Heidelberg, 1974
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Missing Link -
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dihw DIAMANT HOCHLEISTUNGSWERKZEUGE 2016
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Bouabid, A.; Liu, Y.:
Model-based manufacturing and application of
metal-bonded grinding wheels
CIRP Annals 2019, 68(1), page 321 - 324
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P.; Kempf, F. L.:
Methods of analysis for a deeper understanding of
the grinding process
in: Proceedings of the 20 th International Symposium on
Advances in Abrasive Technology 2017; page 945 - 951
10. Denkena, B.; Grove, T.; Bremer, I.; Behrens, L.:
Design of bronze-bonded grinding wheel properties
CIRP Annals 2016, 65(1), page 333 - 336
11. Tavgen’, V.V.; Shinkareva, E.V.; Karpinchik, E.V.;
Zonov, Y.G.:
Oxidation of titanium powder with heating
in an air atmosphere
Soviet Powder Metallurgy and Metal Ceramics 1992,
31(3), page 193 - 196
12. Winterhager, H.; Kohler, A.; Krajewski, W.:
Untersuchung zur trockenen Hochtemperaturkorrosion
von technisch genutzten Titanbasislegierungen
VS Verlag für Sozialwissenschaften: Wiesbaden, 1976
13. Antończak, A.J.; Stępak, B.; Kozioł, P.E.; Abramski, K.M.:
The influence of process parameters on the
laser-induced coloring of titanium
Applied Physics A 2014, 115(3), page 1003 - 1013
14. Lindenau, K., Ed.:
Wirtschaftliche Fertigung mit Schleifen
Carl Hanser Verlag GmbH & Co. KG: München, 2006
15. Thiemann, P.; Dollinger, C.; Goch, G.:
Untersuchungen zum Phänomen Schleifbrand
HTM Journal of Heat Treatment and Materials 2014,
69(3), page 173 - 181
16. Schattauer, A.:
Prozessentwicklung und Charakterisierung einer
anodisch-keramisierten Al-Zylinderlaufbahn unter
tribologischen Aspekten zur Reduzierung der
CO 2
-Emissionen
Dresden, Techn. Univ., Dr.-Ing. Dissertation, 2009
further information: www.ifw.uni-hannover.de
36 no. 4, November 2020

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processes
State-of-the-art laser process measuring
technology for precision machining
Demands for integrated production measuring technology
Finishing processes on grinding machines often
demand exacting tolerances in relation to dimension,
form and position accuracies, as well as highly
accurate surface qualities. Often companies have
empirical values available to fulfil these requirements.
However, with small lot sizes in parti cular
process evaluation on the machine is desirable, as
intermediate measurement on external measuring
machines and the resulting corrections prolong the
processing time for part machining. These control
measures would significantly increase process
relia bility and productivity. Solutions that can be
flexibly used for a wide variety of workpieces are
ideal and preferable.
Possibilities of process measuring technology
in grinding processes
Production engineers have diverse measuring functions
available for process evaluation, which are based on different
principles of production measuring technology. The
measurement of process forces such as grinding forces (Ft,
Fn) or comparative grinding spindle currents, for example,
provide an index for achieving the service life of tools or,
equally important, they enable the determination of fluctuating
allowances, which can influence process stability
and compliance with required tolerances. Tool costs can be
reduced, as excessive dressing is prevented. Familiar acoustic
touch sensors assist so-called contact detection in the
grinding process to reduce grinding time, or moni tor the
true-to-profile dressing process with its envelope curve
functions. Tactile measuring systems such as measurement
and control systems for diameters or workpiece lengths,
pneumatic systems or microsensors for longitudinal expan
sions of spindle systems also support increased process
reliability. There also are other measuring functions, such
as the use of camera or laser systems for process monitoring.
Laser measuring technology in particular opens up
interesting fields of application.
Integration of laser measuring technology into
STUDER universal cylindrical grinding machines
STUDER has more than 10 years of experience in the use
of machine-integrated laser measuring technology, which
has been evaluated for trials in the measurement of grinding
wheels or workpieces. Such fundamental studies ensure
that the company is prepared for future trends in production
technology. With this knowledge and experience
they can respond to current requirements. The systems
used in other industries for tool monitoring have been
further developed STUDER-specifically on the basis of the
latest laser measuring technology, only recently available,
for measuring work-pieces on grinding machines.
figure 1 - example of universal use
The necessary measuring device (see U-profile in figure 4)
is mounted mechanically, similarly to our measuring
probes on our B-axes, which carry the relevant grinding
spindle. In fact, this situation is not an unfamiliar one for
the operators.
The size of this measuring device can be adapted to the
workpiece diameter. The existing air nozzles for blowing
off the workpiece during measurement and the newly developed
dirt screens efficiently protect the laser optics from
the cooling lubricant in the machine. In comparison to
previous models, the laser unit manufacturer also uses an
enhanced, more accurate laser optics. However, the most
striking element from our point of view is the possibility
of generating many thousands of measuring points for evaluation
with the workpiece rotating. This significantly reduces
measuring time. These features have been integrated
into the STUDER-specific measuring cycles. The user is
figure 2 - measuring record for a workpiece
38 no. 4, November 2020

processes
figure 3 - tactile measurement of cutting tools
thus provided with a suitable method for non-contact
measurement for the machining of precision workpieces.
It should also be mentioned that not only different diameters
can be recorded with a laser measuring device, but
also precise control measurements can be carried out on
“interrupted” diameters, such as shafts with keyways or
longitudinal grooves and toothed gears in the diameter
range (see figure 2). The setup and resetting of previously
used tactile in-process gauging devices is omitted, thus efficiency
rises dramatic.
The measuring cycle can be selected as desired after each
machining operation or at the end of the grinding process.
The STUDER software logs the measured values per diameter
(see figure 3) after each measuring cycle. This process
enables the operator to ascertain the quality of the ground
component at a glance.
Typi cal measuring tasks
which are required in this
sector are, for example:
measurement of a tool with
cutting edges, where the
smal lest and largest cutting
edge diameter are determined
in a measuring plane.
Measurement in two different
planes of the cutting
tool, i.e. in different planes
of the measuring cylinder
generated by rotation, gives
the dimension of the desired
taper on cutting tools,
which can now be output.
Depending on the measuring
differences between
the diameter of cutting
edges and guide rails of a
cutting tool in the same
measuring plane, the laser
optics can determine this diameter even with the workpiece
rotating. This being the case for most tools helps to
reduce measuring time.
STUDER measuring cycles can help anyone who wants to
know - before machining and with the tool to be ground
clamped - how large the runout is, from the tool shaft to
the cutting edge diameter at the end of the tool.
Conclusion
The presented strategy for machine-integrated laser measuring
technology expands the possible applications of
process measuring technology in grinding machines. A
precise, universal, non-contact measuring process supports
the user in his efforts to increase efficiency in precision
machining.
Example of application of laser measuring
technology for cutting tools
A very efficient example of the use of an integrated measuring
strategy is the complex machining of small batches
of tools with PCD cutting edges. The question often arises
here as to who is machining whom, the diamond grinding
wheel the tool, or vice-versa. The so-called “closed loop
process” with tactile measuring devices is often used for this
purpose (figure 3). The cutting edges are measured, ground,
measured, etc. in several iteration stages. Diameter toleran
ces of +/- 1.5 micrometer are achieved with this measure,
which is a very good result. An increasing demand
for non-contact measurement has developed for these applications,
as the PCD cutting edges sometimes react sensitively
to tactile measurement. This demand for non-contact
measurement of tools with cutting edges or guide rails
in this tolerance range can now be met with the integrated
laser measuring technology described here (figure 4).
figure 4 - non-contact measurement of precision tools
with laser measuring technology
further information: www.studer.com
no. 4, November 2020
39

processes
Laser light makes VOLLMER a full-line supplier
VOLLMER can always deliver the optimum
sharpening solution, independently of the process,
in order to fully machine rotary tools, circular
saws and band saws.
And thanks to corresponding automation, the VOLLMER
machines are unmanned and ready for use around the
clock. VOLLMER’s most recent innovation is the VLaser
270 laser machine. Using the power of the light and linear
drive technology, PCD-tipped (polycrystalline diamond)
tools can be precisely machined.
VLaser 270 is based on innovative
VOLLMER kinematics
At the core of the VLaser 270 laser machine is its fixed
laser beam guidance with innovative machine kinematics.
The way in which the five-axes are arranged means that the
tool is always machined at the pivot point of the C-axis.
This makes it possible to machine tools with minimal axis
movement and to ensure stable process control. At the
same time, the kinematics enables high path accuracy,
which has a positive impact on the machining accuracy
and quality of the tools. The VLaser 270 can be optionally
equipped with a counter point to achieve even higher
concentricity. This makes the VLaser 270 the first laser
machine on the market to have such a counter point
VGrind 340S for machining small diameters
The new VGrind 340S is one of the party, which has been
specially developed for producing and resharpening the
With the new VLaser 270 laser machine, VOLLMER
becomes a full-line supplier for precise machining of
rotary tools, circular saws and band saws
VLaser 270 laser machine
smallest of carbide tools with a diameter of between 0.3
and 12.7 millimeters. The machine relies on tried-andtested
VGrind technology: it features two vertical spindles
for different grinding wheel sets, which makes it possible
to reduce non-productive times. Five perfectly harmonised
CNC axes achieve interpolation with short travel
distances for the linear and rotary axes, which in turn
reduces the time required to machine workpieces. In addition
to the rotary axes, the linear axes are also designed
as direct drives (linear drives) for the first time.
VHybrid 360 combines the best of two worlds
The VHybrid 360 grinding and erosion machine is also
new from VOLLMER. With this machine, tool manufacturers
can grind and erode various carbide and PCD tools,
combined in one set-up. This machine combines technologies
and experience that VOLLMER has gained in the
fields of grinding and eroding over many decades. The key
component is the VPulse EDM erosion generator, which
sets new standards when it comes to efficiency and surface
quality. From the world of grinding, the ultra-modern machine
concept of the VGrind series ensures high precision
in tool machining.
CHX 840 sharpens circular saws
with high precision
Traditionally, VOLLMER is strongly represented when it
comes to sharpening machines for machining carbidetipped
circular saw blades. On the global grinding technology
market, the VOLLMER machines abbreviated as CHX,
CHP, CHF and CHD are some of the best-sellers. Thanks
to five CNC-controlled axes, the CHX 840 can machine
saw blades with all common tooth geometries - this also
applies to sawing with axial angle and group toothing.
further information: www.vollmer-group.com
40 no. 4, November 2020

processes
Substantial time and cost savings
in the maintenance management
The efficient interaction of ZEISS GUARDUS
and ZEISS Reverse Engineering (ZRE) accelerates
not only the processes and correction loops in
tool maintenance and tool construction. The realtime
knowledge of the MES regarding the quality
state of the manufactured parts and the possible
wear of the production tool offers to organize the
process between tool maintenance and production
in an obviously more efficient way.
gon meshes) of the manufactured plastic part as well as the
measured real data of the used or worn tool.
The result of the correction resulting from the algorithm
and the user entries is an updated CAD model based on
which the tool will be subsequently adjusted by eroding
or milling, for example. The successful use of the software
and adjustment of the tool enable a reduction of the correction
loops by up to 50 %.
The ZEISS GUARDUS users can also increase the efficiency
within this process. The foundation for this is the integrated
database of the MES of all the quality and production
relevant product and process data in real-time as well as
information about the setting up of production facilities,
the attachment of adequate tools to the machine and its
calibration to the planned manufacturing order. During
pro duction the MES collects all the data which are important
for the maintenance intervals and further correction
of tools, such as the manufactured piece number, cycles,
information about the end of the production order and the
stripping down of the machine. The ‘last part’ of the production
order is sent to the testing laboratory for approval.
When measuring this ‘sample’, the person responsible
for quality assurance checks not only the product characteristics
defined in the customer order but also indicators
which inform about the current wear of the tool. This
concentrated expertise of the MES enables you to analyse
the worn areas via a false-colour image within the ZEISS
Reverse Engineering and to correct it, if necessary. The
maintenance management subsequently decides to obtain
more information, whether rework is required or whether
the following production order can still be manufactured
without any quality deviations. Therefore, the loop
between the product and tool as well as between construction
and production is closed.
The software ZEISS Reverse Engineering is a performant
tool for the so-called reverse engineering process. It offers
specialised functions for the quick and easy correction of
injection mould tools. These functions are especially used
in the pilot production as well as for the repair of already
worn tools. In this area it is very important to correct the
tools as quickly as possible so that the series production of
“good” parts can be started or continued. The correction is
carried out within ZEISS Reverse Engineering with three
real data records: the CAD model of the tool, of the product
and the measured real data (e.g. point clouds or polyfurther
information: www.zeiss.com
© shutterstock.com/Vadim Ratnikov
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09 – 10.02.2021 | Digital Event
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www.grindingcongress.com

machining center
Handling system HS flex heavy
Automation solution with up to 1200 kg of transport weight
The handling system HS flex heavy marks the
continuation of Hermle AG’s commitment, lasting
almost 20 years, to the automation of its machining
centers, with the company introducing a
powerful, compact and extremely attractively
priced automation tool onto the market.
The handling system HS flex heavy is designed to be adaptable
to 5-axis Performance-Line machining centers (C 400
and C 650) as well as to High-Performance-Line models
(C 32 and C 42). This means the C 650 is, for the first time,
available automated.
The handling system HS flex is based on several components,
which are supplied and adapted as a complete
unit. Only the workpiece storage modules are installed and
adjusted on site. As a result, the entire installation - with
all Hermle machining centers also being shipped in a
pre-assembled state - is available in a very short time, and
the user can start machining with little delay.
The flat mineral casting bed, on which the three-axes of
the handling unit are operated, offer ergonomically very
friendly access for the operator. The two double-leaf doors,
which have already proven their functional benefits in
Hermle’s robot systems, provide a twofold function. During
a tool change procedure, they prevent access by the
operator, while during machining of the workpiece, they
provide access to the working view position and working
area while also preventing access to the handling unit.
The rotary, lifting and linear axes of the handling unit
enable precise movements of the heavy workpieces up to
1200 kg, including the pallet, between the setup station,
storage modules and the machining center’s working area.
With crane loading of machining centers, workpieces with
even higher weight and dimensions can be moved into
the machine working area. Pallets up to 800 x 630 are handled
precisely. To minimise the sources of potential errors
for the operator, the maximum workpiece height is queried
beforehand at the setup station, thereby preventing
Handling system HS flex heavy with two storage
modules, adapted to a C 650 five-axis machining center
42 no. 4, November 2020

machining center
workpieces with dimensions
beyond specified dimensions
from being fed in. The maximum
work piece dimension
that can be handled is 800 x
630 x 700 mm (w x d x h).
Excellent accessibility for manual tasks as well
Sectional view
Sectional view
Particular attention has been
paid to the development of the
storage modules. One module
is installed as standard, and the
adaptation of a second module
is optionally possible. The
modules are structured as a
rack, offering maximum custo
misation potential in the
pallet/workpiece arrangement.
Up to three rack bottoms with
a total of up to nine pallet storage
pockets can be ordered per
module. If two storage modules
are used, up to 18 pallet pockets
are then available. Using
a specially developed storage
gen erator, which tests both the
per mitted weights and dimensions
(given that a variety of
machine models are possible),
the storage arrangement can
be defined quickly and easily.
The HS flex heavy, the pallet
changer and the RS 05-2
robot system are controlled
and managed using the proprietary
and convenient Hermle
Automation Control System, or
HACS. HACS allows for smart
order management, which intuitively
aids the operator in
his daily business via a software
solution that can be operated
by means of a touch panel. The
transparent representation of
the orders and required op er a-
tor actions reduce the orga nisa
tional downtimes and maximise
productivity of the plant.
When combined with the
Hermle Information Monitoring
System, which displays machine
states in real time and can be
shown on any tablet, desktop
or smartphone, these two
software tools are collectively
a cor nerstone of Industry 4.0-
capable use of Hermle ma chining
centers.
further information: www.hermle.de
no. 4, November 2020
43

machining center
OPEN HOUSE ONLINE:
New machining centers increase productivity
and precision
Maximum
precision for
large components.
The new CHIRON
22 series celebrated
its global debut at
the OPEN HOUSE
ONLINE - one of the
first online inhouse
exhibition for mechanical
engineering.
The DZ 22 W
five-axis with a
spindle distance of
600 mm is based on the same machine platform as the
proven 16 series and was developed in response to current
customer requirements in the automotive industry. It
boasts precise, dynamic machining, high technical availability
and is particularly impressive in the complete
machining of large steel and aluminum components, such
as electric motor and transmission housings, oil sumps or
chassis components.
High productivity and minimum setup
when producing complex workpieces
Thanks to the proven moving gantry design, a particularly
rigid machine bed and active component cooling, the
DZ 22 W five-axis achieves a high level of precision even for
very large components. Short cycle times are effortlessly
achieved with high axis acceleration, short changeover
times and rapid traverse speeds. The integrated workpiece
changing device, which enables blanks and finished parts
to be loaded and unloaded during machine operation,
further increases productivity. The two sets of 77 tools in
the magazine can be used to machine workpiece families
as well as complex workpieces with minimum setup. Two
different main spindles are used depending on the task: a
high-speed spindle for workpieces made from aluminum
or aluminum alloys and a high-torque spindle for large
tools and hard-to-machine materials. All additional units,
for example the cooling, hydraulic or extraction systems,
are integrated in the machine so that they take up very
little space. The 22 series is available in different configurations:
as a DZ 22 S version with direct loading or as an
HSK-A100 machine. Customers can choose between a ball
screw drive and a linear direct drive. There are also plate
variants available for four-axis or five-axis machining.
Maximum
efficiency for
the aviation
industry
The demanding ma -
chining applications
in the aviation industry,
where components
are mostly
machined from a
solid block, require
machining centers
that combine optimum
milling perfor
mance with
maximum precision.
The new CHIRON FZ 16 S five-axis with HSK-A100 is
tailored to the high requirements of this industry. It has
a powerful main spindle with a torque of 400 Nm and is
predestined for machining difficult structural components
made from titanium or nickel-based alloys like INCONEL.
The particularly large HSK-A100 interface and the proven
moving gantry design, which ensures high static and
dynamic rigidity, form the basis for particularly high
machining rates and machining very deep cavities. The
powerful drives of the machining center provide the required
dynamics. The new FZ 16 S five-axis with HSK-A100
also impresses in terms of precision thanks to a robust
basic design and particularly high thermal stability.
CHIRON DZ 16 W now with VariocellUno
At the OPEN HOUSE ONLINE, CHIRON presented the 16
series with the compact VariocellUno automation unit,
comprising a handling robot and workpiece store, for the
first time. The new version was designed for a particularly
productive exchange of blank and finished-part pallets
during machine operation in series production and makes
it possible to machine a large number of workpieces in very
short cycle times. The workpieces are handled by a six- axis
robot on the DZ 16 W. A variety of standardized options sup -
port operators in interpreting and implementing projectspecific
requirements. The new machining center with
auto mation is available with drawer storage, palletizer or
workpiece conveyor belt depending on individual customer
requirements. A large rotating door makes the machine’s
working area very easy to access. The automation cell can
also be moved for setup and maintenance work. The compact
automation unit can be retrofitted and is also available
for the STAMA MC531.
further information: www.chiron-group.de
44 no. 4, November 2020

components
Further development in clamping technology
Flexible 5-axis clamping system
with two functions
The HENRICH KIPP plant supplements its portfolio with the KIPPflexX 5-axis vices,
which combine a pull-down function with the functionality of a standard vice
The HEINRICH KIPP WERK has made a further
development to the proven 5-axis clamping
system: the KIPPflexX is a versatile solution for
any 5-axis milling machine, which can be used
both for raw parts as well as for pull-down clamping.
This is unique on the market. A new feature is
the user-friendly rapid adjustment using a crank
handle.
The KIPPflexX clamping system which KIPP has brought
to the market combines two functions: the patented pulldown
function is particularly suitable for pre-machined
workpieces. Thanks to the symmetrical design structure
of the ratchet lever, the workpiece is always centered, thus
ensuring high repeat accuracy. This system can also be
used just like a standard vice: if clamping raw parts, jaw
plates with pins are used and these are pressed positively
into the material, thus making time-consuming preforming
processes unnecessary.
The support height of 180 mm ensures optimal accessibility
for the tool on 5-axis milling machines. The flat
guide ensures greater stability and rigidity in the clamp ing
system, which provides an exceptionally high retaining
force of 52 kN. For the clamping range on a base plate, the
user needs three adapter shafts and one extension shaft.
With another baseplate and additional extension shafts,
the clamping range can be extended substantially.
KIPPflexX is suitable for mounting on machine tables
with T-slots or threaded holes. The central hole ensures
concentric alignment. The baseplate has alignment slots in
the longitudinal and transverse directions.
However, the 5-axis clamping system can also be applied
to any grid elements or directly to zero point clamping
systems. In this case, the clamping physics and intelligent
force distribution ensure that only limited torques are
transferred to the machine table.
further information: www.kippwerk.de
no. 4, November 2020
45

components
Multi-site Tool Management 4.0
MAPAL takes over tool management at Hitachi Automotive Systems Group
in Turkey, Poland and Mexico
For manufacturing companies, procuring and
preparing tools requires a great deal of time and
effort that demands both capacity and competence.
For that reason, the Hitachi Automotive
Systems Group has entrusted tool management for
the entire brake manufacturing process at three
of its locations - in Turkey, Poland and Mexico, -
to MAPAL. By doing so, the company benefits not
only from tool management but also from the
opportunities provided by digital connectivity.
Chassis Brakes International has been part of Hitachi
Automotive Systems since 2019. The acquisition made
Hitachi Automotive Systems one of the world’s largest
brake manufacturers. “In Hitachi Automotive Systems’s
brake business unit we manufacture disc brakes, drum
brakes, electric parking brakes and rotors,” says Hubert
Klehenz, the company’s global sourcing director for braking
systems. The products are used in cars, light commercial
vehicles and two-wheeled vehicles.
At its three factories in Turkey, Poland and Mexico,
Hitachi Automotive Systems Group primarily manufactures
disc and drum brakes. “We have been success -
fully working with the Turkish factory in Bursa for 13
years,” recalls Frank Stäbler, head of Tool Management Services
at MAPAL. Over time, the two companies expanded
their collaboration. “Following our work at the Turkish
factory, Hitachi Automotive Systems Group entrusted
us with the tool management for its facility in Wrocław,
Poland,” says Stäbler. Their most recent partnership is in
Querétaro, Mexico. In 2017, when it was still operating as
Chassis Brakes International, the company had opened a
completely new plant there.
Mastering global challenges with
worldwide on-site support
Hubert Klehenz’s team was looking for a partner company
that would be able to take over complete responsibility for
tools at the plant in Mexico: “In order to deal with global
challenges and global projects, we need a tool-management
provider that can support us worldwide,” says
Klehenz. Brake manufacturer’s main concern was finding a
provider to work to the same standards as they themselves
did, and deliver at a consistently high quality.
“Brakes are among the most critical safety features of
every vehicle, and they need to operate perfectly under
all circumstances,” Hubert Klehenz points out. In order to
meet the high quality, safety and reliability requirements,
brake manufacturers machine each part with the greatest
care. “We receive the unfinished parts for brackets and
In the setting room an employee measures the special
disc milling cutters from MAPAL (copyright HITACHI)
brake calipers made of aluminium and cast-iron and take
care of the entire machining and assembly process.”
In doing this, Hitachi Automotive Systems Group needs
to eliminate all conceivable potential errors in order to ensure
that none of their products are faulty. This approach
is used across the board in the automobile industry and
is the reason that the brakes in modern cars almost never
fail. However, it does lead to increasing expenditure in
terms of the equipment and tools used in brake manufacturing.
Only components and processes that have been
confirmed to rule out failures are used.
Focusing on core competencies
“That makes it even more important for us to focus on our
core competencies and place our tool management in the
hands of a company that specialises in precisely that part
of operations,” says Klehenz. “By using an external tool
management company, we are able to ensure that we are
using the best tools - and we also receive technical support
and assistance in cost-optimising our processes,” he
explains further.
After the runaway success of their partnerships in
Turkey and Poland, Hitachi Automotive Systems Group
decided to continue working with the precision tool manufacturer
in Mexico as well. “MAPAL’s structure is sim -
ilar to ours, which enables them to support us at a regional
level,” says Klehenz. “On top of that, MAPAL offered us a
rea dy made solution for implementing the operations at
our factories.”
All-round tool management
“We implemented an all-round tool management system
at the plant in Mexico - we are responsible for procuring
and providing all tools,” says Stäbler. That includes a tool-
46 no. 4, November 2020

components
setting area. “It helped that our new MAPAL site at Frhenosa
is very close by.” That means short transport distances and
quick reaction times are the order of the day.
At Querétaro, MAPAL implemented - and continues to
implement - all the components of the modular tool management
system. Amongst other things, it installed its own
UNIBASE-M tool dispensing system, as well as a UNISET-C
setting fixture. On top of that, as in Turkey and Poland, the
MAPAL service includes a complete tool-setting area. “We
make use of the complete service, from the procurement
of various consumables - including the tools - all the way
through to the dispensing of materials and stock monitoring
with automatic re-ordering. MAPAL also takes care of
the setting and installation of the tools. When we receive
the tools, they’re already on the machine and ready for operation,”
Hubert Klehenz explains. MAPAL is also responsible
for all regrinding and reconditioning procedures.
And that’s just the tip of the iceberg when it comes
to tool management: “While all this is going on, MAPAL
constructs tools and chucks that perfectly match our
manu facturing standards and make high-performance,
eco nomical production possible.” For example, MAPAL is
continually working on ways to help Hitachi Automotive
Systems Group to reduce cycle times and increase production
outputs.
Tool Management 4.0 - an impressive service
In the interests of transparency and even more efficiency,
MAPAL further enhanced its conventional tool management
system in 2019 and now offers Tool Management 4.0.
For this the tool manufacturer uses an open-cloud platform
from c-Com GmbH. MAPAL is now able to illustrate
the tool processes to the customer transparently and
digitally.
Hubert Klehenz is pleased: “Tool Management 4.0 has
definitely given us a boost when it comes to digitalisation
and all its benefits for manufacturing.” He says that the
direct transfer of information makes a difference, for example
in the automatic restocking of inventory, which
ensures that all necessary materials are available. “We have
significantly more flexibility when replacing tools. As a
MAPAL has designed disc milling cutters as special tools,
allowing the machining requirements of Hitachi Automotive
Systems Group to be achieved most efficiently (copyright HITACHI)
result, the machines have noticeably less downtime,” says
Klehenz, naming just one of the benefits. On top of that,
Hitachi Automotive Systems Group can now digitally track
its tools and receive automated reports about them.
“Having MAPAL as our tool manager gives us maximum
transparency across all locations in terms of technology
and machining processes, and in terms of cost,” says
Klehenz. MAPAL calculates the cost per part for tool management
at Hitachi Automotive Systems Group.
Hubert Klehenz lists the following tangible improvements
resulting from tool management:
➞ no more difficulties finding the right tool
when you need it
➞ completely accurate stock inventories - which
has a positive effect on purchase costs and
tied-up capital
➞ more resources for activities that add value -
like brake installation - as MAPAL manages
the set-up and adjustment of tools
➞ each plant regularly receives its own key figures,
making it possible to monitor the costs and
outputs of individual machines
➞ productivity is increased as a result of
amendments made on the basis of these figures
➞ Hitachi Automotive Systems Group has access
to the newest technologies when it comes to
tools and their applications
➞ MAPAL takes care of the reconditioning of the tools,
leading to a longer service life and higher
maintenance efficiency
Global and local cooperation
It’s not just the overall global collaboration that runs
like clockwork. The cooperation on-site is what’s most important.
“The two head offices have made a global agreement,
but it’s the local MAPAL locations that make a real
difference in implementing our requirements at a regional
level,” says Klehenz.
During day-to-day operations on site, the company’s
production managers meet regularly with the MAPAL
employees. Together they discuss the production schedule
and analyse the most important key figures. These include
machine and tool failures, output figures and productivity.
Every year, there are workshops at the three factories
in Turkey, Poland and Mexico to share best practices
and harmonise processes across the different locations.
Having all the data digitally recorded by c-Com facilities is a
great help.
And cooperation is going to be significantly increased
in the future: “We are now going to assess additional
locations and units to identify where a similar tool
management system would be helpful and increase efficiency,”
says Klehenz. In doing this, the three current
locations will act as model plants providing evidence of
the increased efficiency.
further information: www.mapal.com
no. 4, November 2020
47

components
New motor spindles save users second machine
SAUTER is presenting a new series of motor
spindles with exceptionally high power density.
The spindles are suitable for turning/milling
centers and three- and five-axis milling machines
and can be used in conjunction with a B-axis if
required. The market innovation: thanks to a
new cartridge system, users can implement two
different machine concepts in the same installation
space, thus saving a second machine tool.
In the Speed Drive ® variant, the motor spindles
achieve very high speeds of up to 30,000 rpm,
and in the Torque Drive ® variant, torques of up to
450 Nm are possible.
Previously, two differently configured machine tools were
necessary to perform milling operations with high torques
or high speeds. Thanks to the new cartridge design,
SAUTER’s motor spindle series makes it possible for the
first time to implement both applications on just one machine.
If, for example, it becomes necessary to change
from torque drive to speed drive motor spindles, all that
is needed is to replace the spindle cartridge. Furthermore,
only minor adjustments need to be made in the control
cabinet area. “Simply change the cartridge and off
you go. This allows users to react extremely quickly and
flexibly to changing requirements. They also save themselves
the very expensive investment in a further
machine,” says Manuel Keppeler, Head of Mechanical Development
at SAUTER.
The new series of motor spindles also offer maximum
flexibility in other respects: the spindles are available with
different types of lubrication, clamping, interfaces, and
milling heads. The pre-installed sensor technology also
comes from SAUTER. The expert for tool turrets and tool
SAUTER’s new motor spindles make it possible for
the first time to achieve both high speeds and
high torques in just one machine
carrier systems supplies its new motor spindles with integrated
plan system control, leakage testing, and temperature
and vibration monitoring on customer request. This
means that the duty cycle of the overall system, process
stability, and metal-cutting volume can be varied to suit
customer requirements.
Implement all requirements in one machine
The new SAUTER system is currently being used to manufacture
products for the aerospace, mechanical engineering
and medical industries in particular. However, the possibilities
are far more varied, ranging from classic 2-axis to
5-axis machining, from round material with a single bore
to turbine blades. With SAUTER’s new motor spindles in
conjunction with a rotary axis such as a B-axis, for example,
users can implement all requirements in one machine, as
far as its size allows.
Motor spindle without housing
Motor spindle with housing
further information: www.sauter-group.com
48 no. 4, November 2020

components
Integrate many tool grinding machines
on one filtration system
Optimally filtered cooling lubricants are the
prerequisite for higher productivity when grinding
carbide and HSS tools. Especially when a
great number of grinding machines on a single
filtration circuit, a powerful central filtration
system for cleaning contaminated grinding oils or
aqueous coolants becomes indispensable.
VOMAT a company specializing in metalworking fluid filtration,
from Treuen, Germany, provides stand-alone filtration
systems with their FA series - as well as central filtration
systems with their ZFA series-machines, that can be config -
ured to suit any given production situation. VOMAT
systems increase the life of the cooling lubricant thanks
to high-performance pre-coat filters and automatic ondemand
flushing and back-flushing technology.
Economic, process-reliable tool grinding with high quality
results is only possible with extremely clean grinding
oils. VOMAT is a specialist for ultra-fine filtration of cooling
lubricants in the metalworking industry. The product
portfolio includes solutions for stand-alone and central
systems as well as individual customer-specific special
configurations with central and decentralized functions.
Steffen Strobel, technical sales manager at VOMAT states:
“The larger the production batches are and the more grinding
machines are integrated into the filtration process, the
more likely our ZFA central filtration systems are the right
solution. They can be precisely adapted to the respective
production conditions and needed coolant flow rates. Further
capacity extensions are also possible, in case of later
production expansion. Our ZFA systems grow with changing
requirements thanks to their modular design. Modular
units such as frequency-controlled ma chine pumps,
The central filtration systems from VOMAT consist of
separate modules that can be scaled up in steps of 1,200 liters
tanks and cooling components
allow for this
flex ibility. It also results
in maximum filtration
performance indifferent
phases of a company’s
development.”
Thanks to flexible modular units
such as frequency-controlled machine
pumps, tanks and cooling
components, the ZFA-system
can adapt to changing system
requirements
VOMAT filtration systems
have an on-demand
backwash system
which automatically
starts once it senses,
that the filters have reduced
throughput. In
addition VOMAT systems,
always separate
dirty and clean oil
100 %. Due to the backflushable
high-performance
pre-coat filters,
cost-intensive filter
aids are unnecessary.
The cen tral control unit links all system modules
and controls external components such as machine supply
pumps (MSP) etc. In addition, remote diagnostics is
available via an internet connection. Steffen Strobel: “The
data exchange between the machine tool and the filtration
system takes place via control signals. When two or
more machines are connected to one filtration system, a
machine interface box is required. The control signals can
be provided by either the filtration system or by the machine
tool”.
The ZFA 1200 is the base model of VOMAT’s central
filtration systems and is capable to filter to a fineness of
NAS 7 quality class (3-5 µm). The cooling capacity of the
PLC-controlled cooling unit is designed to fit any given
production process. The AC generated heat is dissipated
via an external condenser. VOMAT also offers cold watercooling
as an option.
The ZFA 1200 filtration unit is very compact with dimensions
of 1200 x 1200 x 2200 mm (l x w x h). The base
unit can be expanded in steps of 1,200 liters thanks to the
large selection of modules and additional optional components.
The sludge disposal volume is reduced to a minimum
due to minimal drag-out loss. The recyclable material
is disposed of fully automatically directly into the transport
containers provided by the recycling companies. The
residual moisture of the recyclable carbide and HSS swarf
is approximately 5-10 %.
further information: www.vomat.de
no. 4, November 2020
49

impressum
ISSN 2628-5444
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CERATIZIT Group.................................... 26
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CHIRON Group......................................... 44
DeburringEXPO........................................ 30
Dormer Pramet........................................... 8
Fritz Studer AG.......................................... 38
DP Technology Corp................................31
HEINRICH KIPP WERK
GmbH & Co. KG.........................................45
IFR International Federation
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IFW Institute of Production
Engineering and Machine Tools...........32
KYOCERA FINECERAMICS LTD...........16
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Jakob Lach GmbH & Co. KG............21, 22
Maschinenfabrik
Berthold Hermle AG................................ 42
Paul Horn GmbH.................................18, 19
PLATIT AG.................................................... 6
SAUTER Group.......................................... 48
Schwäbische Werkzeugmaschinen
GmbH............................................................27
Supfina Grieshaber
GmbH & Co. KG........................................ 26
VOLLMER WERKE Maschinenfabrik
GmbH........................................................... 40
Vomat GmbH............................................. 49
Walter AG.................................................... 20
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advertising index
CERATIZIT Deutschland GmbH............................................................inside back cover
FILTECH................................................................................................................ page 3
GRINDING CONGRESS 2021............................................................................... page 41
Lach Diamant Jakob Lach GmbH & Co. KG.........................................inside front cover
PLATIT AG.........................................................................................................back cover
PuK........................................................................................................................ page 21
Rollomatic SA Headquarters................................................................................. page 27
STUDER ..................................................................................................................... cover
TYROLIT Schleifmittelwerke Swarovski KG......................................................... page 31
WiN....................................................................................................................... page 37
ZECHA Hartmetall - Werkzeugfabrikation GmbH.............................................. page 13
50 no. 4, November 2020

Coating for maximum
performance by CERATIZIT
Find out more at:
cutting.tools/en/dragonskin
CERATIZIT is a high-technology engineering
group specialised in cutting tools and hard
material solutions.
Tooling the Future
www.ceratizit.com