hp tooling 2022 #1

ISSN 2628-5444
high precision tooling
Machine Tools, PCD, PVD, CVD, CBN, Hard Metal 2022 – 1
»Contour-profiled«
Step into the future...
...deep grinding
fast
precise
cost-effective
®
since 1922
celebrates its 100 th anniversary
www.lach-diamant.de
Titelbild hp tooling_contour_01/22.indd 1 31.01.22 12:31
■ Intelligent generating grinding – quality assurance for e-transmission gears ■ Plasma etching optimization on
complex geometries ■ Future of tool grinding ■ More efficiency in the manufacture of cardiovascular products ■

editorial
Spring fever...
Eric Schäfer
editor-in-chief
...is something else, but it’s not
just us trade journalists who are
feeling excited these days. This
is probably the case for everyone
in the industry who will finally
be able to visit trade shows again
this spring. The trade fair duo
TIMTOS and TMTS in Taiwan
has already started at the end
of February – despite travel
restrictions. In Germany GrindTec, the leading international
trade fair for grinding technology, is on the agenda in March.
And finally again personal meetings, even if still under
pandemic-conditioned precautionary measures.
much higher demands on manufacturing precision despite
their simpler design. Precision is also the keyword in tool
grinding. At GrindTec machine manufacturer Haas will be
showing what the future of tool grinding could look like.
Not only precision, but also efficiency plays a decisive
role in manufacturing processes in the medical technology
industry. How the most precise laser control and positioning
systems contribute to efficient production in the manufacture
of cardiovascular products is another highlight you can read
about in this issue. All this can only be a small foretaste of
future events. Because one thing is certain: we can expect a
hot trade show summer.
This issue of hp tooling is also about grinding applications.
We take a detailed look at generating grinding in the pro duction
of gearboxes for electric cars. These, by the way, place
www.harnisch.com/hp-tooling/en/
…have you already been here this year?
Eric Schäfer
editor-in-chief
Milling competence
right down the line
■ 45° Milling - Smooth cut and high metal
removal at extremely smooth running
■ 90° Milling - Highest productivity, cost
reduction and optimal distribution of cutting
force
■ HFC-Milling - High metal removal under the
most difficult conditions
■ 3-D Milling - Universal applicable tool
system for mould and die
■ Solid carbide milling - Over 1000 products
for every application
www.boehlerit.com

table of contents
cover story
LACH DIAMANT looks back on 100 years – 11 th part
«Contour-profiled» shows its claws 6
materials & tools
Automatic profile changing system awarded 10
Machining carbide with PCD solid head milling cutters 11
Hard, harder, SteelCon 12
Slot milling of narrow grooves 13
Plasma etching optimization on complex geometries
made possible by PLATIT’s 3D etch indicator
R. Zemlicka, Y. Li, P. Tapp, H. Bolvardi, A. Lümkemann 14
Range of carbide rods and purpose-built solutions extended 17
Stable process and improved surface finish thanks to vibration-damped boring bars 18
processes
Production systems and manufacturing technologies
for chassis and powertrain of rail vehicles
Manfred Berger, MAG IAS and Leo Schreiber, BOEHRINGER 26
Intelligent generating grinding –
quality assurance for e-transmission gears already on board 30
Flexibility, transparency and cost savings 34
CNC chamfering 35
machining center
Tornos: a source of strength to medical device manufacturers around the world 36
Future of tool grinding “Dear tool grinders, don’t say later that you didn’t know” 38
The latest grinding machine development with an innovative machine concept 40
Top productivity for large workpieces 41
components
More efficiency in the manufacture of cardiovascular products 42
We don’t have to be there to be there 44
Live tool speed increaser realizes 9X tool cost savings in less than a year 45
New CNC software simplifies usage of latest five-axis machine tools 46
Clear conditions for tool grinding 49
news & facts 19
fairs 21, 50
impressum & company finder 51
4 no. 1, March 2022

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cover story
LACH DIAMANT looks back on 100 years – 11 th part
Poly – poly – or what?
«Contour-profiled» shows its claws. A renaissance for
the metal-bond diamond and CBN grinding wheel.
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 excited to have this pioneer of technol ogy share
some insights from his 61 years of professional experience
in the diamond tool business. This time only a few
historical remarks – but indeed most relevant regarding
the trade shows in 2022.
The attentive reader may wonder whether the author has
chosen the wrong title for this series “Poly – poly – or what?”,
since he is writing about diamond and CBN grinding wheels.
Wikipedia provides the (comforting) answer: “Poly, from
the Greek, a word stem found in many German loanwords,
meaning “much, or many”… The author is relieved and
points out how many individual CBN and diamond grains
are present in the grinding layer, depending on the desired
concentration – a truly polycrystalline structure.
By comparison, the “aggregates”, commonly known as
polycrystalline inserts since 1973, are “baked” during highpressure
synthesis and studded with many, many microscopic
CBN and diamond grains; “baked” so compactly and
sturdily that they changed the world of machining, practically
providing a single cutting edge.
Back to the grinding wheels: “Bite”, yes – but “claws”?
This requires a brief look back into the history of metalbond
grinding wheels, and in doing so I found the following
excerpts from the book “Diamanten im Dienste der Industrie“
(a translation from the English original “Industrial Applications
of the Diamond” by Norman R. Smith) fascinating:
“The use of diamonds for grinding hard materials has been
known for hundreds of years. Already in 1824 Pritchard used
diamondiferous wheels for manufacturing diamond microscope
lenses. These wheels were actually produced by
hammering diamond particles into the iron body. By the
middle of the century, these one-layer diamond wheels were
already commonly used. It is known that differently sized
natural diamand grains were hammered into copper coins
for the production of small diamond wheels. It is very likely
that such hammered diamond wheels were used to grind the
first carbides (HM).
Many patents followed, based on a wide variety of different
procedures to produce these kind of grinding wheels. Most
procedures utilized cold pressing and sintering or infiltration
methods still used today. It is also worth mentioning that,
Example of a popular application of metal bond
diamond grinding wheels in the 60’s and 70’s
in 1927, Krupp in Germany developed “Widia”, a cemented
carbide, initially meant for drawing dies for wire drawing,
which presented new challenges to the –up to now – small
market for diamond wheels. The resin-bondgrinding wheel
with today’s quality was still far from being invented. In
addition to the natural diamond grains, a rubber-bond wheel
was available for polishing tasks until the mid fifties.”
A breakthrough for grinding with diamonds
Until the early 1970’s, metal-bond diamond wheels were
still used on simple tool sharpening machines (Simon L 15),
e.g. for grinding chip grooves on hardened carbide turning
tools, mainly because of their form stability and hardness;
or as pointed profile wheels on optical profile sharpening
machines (example PTW).
Until today the glass industry is an exception which, without
diamonds, could not have gifted us with gems such
as crystalline glasses. One would hear similar stories from
ceramics manufacturers. The year 1955 brought a breakthrough
for grinding with diamonds, the development of
diamond grain synthethis, which first became available two
years later to diamond tool manufacturers.
6 no. 1, March 2022

cover story
Schematic picture of a metal bond diamond profiling
grinding wheel, «contour-profiled», during deep grinding
of a threading insert – cost efficient: one instead of three
«Contour-profiled»
shows its claws – the diamond grain,
exposed by the EDG procedure, available up to
90 % maximal removal or chip formation
Ten years later, the innovative ability to metal-coat diamond
grains completed this breakthrough. Thanks to the
metal coating, the diamond grain could be securely fastened
to the grinding wheel’s resin – with the result that the abrasive
grain could be used up to 80/85 % until it broke out of its
bonding.
Suddenly it was possible to use diamond grinding wheels
even for rough grinding; until then only silicon-carbide
grinding wheels were recommended for rough grinding.
Polyamide grinding wheels were the highlight for this
development for deep grinding of carbide and hardened
steel, developed by the manufacturers Winter & Son and
LACH DIAMANT, e. g. Gresso® (Winter) and tressex® (LACH
DIAMANT). These innovations also contributed to the
boom-like development of the carbide tool industry.
Resin versus metal-bonds
Grinding wheels with metal-bonds could not hold up to this
development – apart from their edge stability and profile
retention, they were inferior to the high-performance grinding
wheels based on phenole and polyamide resins as well as
with hybrid and ceramic bonds. The CBN or diamond grains,
closely embedded into the metal-bond, simply did not allow
for enough chip space for fast, erosive grinding.
To manufacture complex components, modern CNC-controlled
tool sharpening machines allow for a fully automated
exchange of different grinding wheels, but the disadvantage
of the bonds used, compared to the metal-bonds, remains.
Patent “Procedure and device for machining metal bond
materials” (EP0076997) with priority of 1981-10-05
Increasing cost pressure in mass production, and grinding
more and more frequently requested profile components
– concave and convex structures with maximal
profile precision of up to 2-4 µ – led to a “déjà-vu” at LACH
DIAMANT and the renaissance of metal-bond diamond and
CBN grinding wheels.
One plus one equals two. Firstly, the discovery of spark/
electrical discharge grinding in 1978, and secondly the European
patent:
“Procedure and Device for Machining Metal-bond Materials”
(EP0076997) with priority of 1981-10-05.
The additional expertise relative to the electric discharge
grinding (EDG) procedure, developed by LACH DIAMANT –
superior to the EDM wire procedure – combined all of the advantages;
thanks to the form electrode broadly set to the metalbond
grinding wheel during profiling, all of the following is
possible: concave or convex profiles; high precision, even for
inner profiles with 2 - 4 µ; even a zero-radius is possible. Since
even grain sizes of 180 µ can be processed, a large chip space
(with grain protrusion of up to 90 %) is available to users during
the grinding process.
Deep grinding revolutionized
It can rightly be argued that the «contour-profiled» procedure,
developed by LACH DIAMANT, revolutionized deep
grinding. The «contour-profiled» profiling grinding wheels
and the sharpening machine «mini-contour», especially developed
for the EDG-Plus dressing procedure, were first introduced
at EMO 2017 in Hanover.
no. 1, March 2022
7

cover story
Product manager Alexander Kern chose a few especially interesting
cases from the abundance of actual customer experiences,
and the results speak for themselves:
Deep grinding of solid carbide threaded inserts from the
solid with «contour-profiled» grinding wheels
Another manufacturer’s resin-bond diamond grinding wheels
were compared with a metal-bond «contour-profiled» profile
grinding wheel. For this application three resin-bond wheel
sets with the dimensions of 150-3-5, form 1A1, 150-4-5-45°,
form 1V1, and model design 150-3-5-R1, form 1F1, were
clamped consecutively onto the grinding mandrel.
By comparison, the «contour-profiled» profile diamond
grinding wheel had a width of 15 mm and a diameter of
150 mm. The wheel geometry was manufactured according to
the contour of the threading insert so that only one wheel was
needed to produce the insert.
The solid carbide (K30) inserts were produced via deep
grinding on a tool sharpening machine, using emulsion of
3-5 %, and with a nominal capacity of 20 kw.
‣ A: operating parameters of the resin-bond wheels
After 100 inserts the wheels had to be taken off the
machine, due to loss of profile, and had to be profiled
on an external dressing machine. With an usable grinding
layer height of 5 mm, and assuming 33 dressings, this
would result in a tool life of 3,300 finished inserts.
The total projected cost for solid carbide inserts would
be 9.73 EUR per insert. This cost calculation considers
cost for abrasives at 0.075 EUR per insert, as well as
machine costs and additional setup times due to the
necessary dressing procedures.
‣ B: operating parameters of the «contour-profiled»
metal-bond profile diamond grinding wheel
Compared to the resin-bond wheels (A), the «contourprofiled»
metal-bond wheels had to be taken off the
machine only after 2,300 finished inserts in order to
guarantee a profile precision of 0.005 mm. With an usable
grinding layer height of 0.005 mm and assuming 50
dressings, this would result in a total tool life of 115,000
finished inserts for the «contour-profiled» wheel (B).
Comparison of operating parameters of resin bond wheels to
metal bond profile diamond grinding wheel «contour-profiled»
EDM wire procedure versus
EDG spark erosion procedure
Over the last three years, the successes of «contour-profiled»
became known within the industry for revolutionary cost
and time savings in deep grinding carbides, ceramics, hardened
and even soft steel. Market insiders did not fail to notice
that even suppliers of EDM wire machines addressed this
issue. I almost gained the impression that customers as well
as competitors were led to believe that the possibilities of the
profiling procedure developed by LACH DIAMANT were
simply the same, 1:1 so to speak. This strikes me as strange.
New EDM wire machines are advertised with statements
such as “0.05 mm precision, porous structures on surface
topology of the grinding layer as well as highest repeatable
precision, erosion wires of 0.1 mm are capable to profile
A
resin-bond wheels
B
«contour-profiled»
metalbond profile
diamond grinding wheel
cost of wheel 3 x 245 = 735 € 1,093 €
v s 24 m/s 20 m/s
a e ges 3 mm 3 mm
v f 15 mm/min 25 mm/min
t s 3.35 min 2.40 min
dressing cycle after 100 inserts 2,300 inserts
dressing amount 0.15 mm 0.1 mm
dressing time,
including setup time
approx. 15 min
approx. 30 min
The total projected cost for solid carbide inserts would be
6.8095 EUR per insert. This cost calculation considers
cost for abrasives at 0.000095 EUR per insert, as well as
machine costs. Considering the high tool lives, setup
costs were negligible.
The EDG-plus sharpening machine profiles with top precision,
even for grain sizes of up to 170 μ, without having to stumble
over up to 90 % exposed diamond or CBN bodies, compared to
EDM wire procedure; it is not without reason that here at
LACH DIAMANT we refer to the «claws» of our so-called
«contour-profiled» grinding wheel, whether with concave or
convex profile which provide maximal removal amounts due
to the cleared chip space
8 no. 1, March 2022

cover story
Example of a multi-part
«contour-profiled» metal
bond CBN grinding
wheel, Ø 400 x 110 mm,
on an «EDG-plus-minicontour-profiled»
EDG
sharpening machine –
during service, profiles
can be resharpened with
highest precision and
repeatable quality for
high tool times
this new technology – from the change of resin-bond or
hybrid grinding wheels to the metal-bond «contour-profiled»
grinding wheel.
More than bite
First of all we should focus on tool life; this is an area in
which metal-bonds have always been superior to any other
bond variations. However the structural design typical for
this type of manufacturing, does not provide a lot of room
for the embedded diamond or CBN grain for long-lasting
chip formation. What does the “hot EDM wire” do when it is
almost – as one should visualize it – “stumbling” over the single
abrasive grains and as it is continuing its path in a wavelike
fashion? One thing should be clear: the EDM “hot wire”
is not able to cut the protruding diamond or CBN grains.
The EDG procedure is different. Here the electrode moves
towards the grinding layer as in deep grinding; the wheel will
be profiled with highest precision, concave or convex. Profile
widths of 200 mm and more as well as the production of
«contour-profiled» grinding wheels with, at present, up to
600 mm diameter are possible.
In doing so, the «contour-profiled» wheel shows – depending
on the size of the diamond or CBN grain – not only its
“bite” but also its “claws”, even at a grain size of 180 µ.
With the latter, the «contour-profiled» grinding wheel profits
from a trailblazing bond technology which exposes each
grain up to 90 % and holds it in place, even during aggressive
deep grinding tasks; «contour-profiled» becomes a “milling
wheel” with until now undreamt-of potential for grinding
carbides, hardened steel, ceramics and even soft steel.
«Contour-profiled» CBN grinding wheel with test
template for a hair trimmer – with a profile depth
of 13.5 mm and a width of 0. 5 mm;
operation during deep grinding
We are indeed experiencing a renaissance of the metalbond
diamond and CBN grinding wheel.
Horst Lach
grinding layers in metallic bond matrix with diamond or
CBN grain sizes of up to 46/50 µ, with a wheel diameter of
max. 150 mm.”
However, we can check these attributes off as doable – but
we are not including into our efficiency calculation the enormous
amount of wire needed for contouring the processed
profile. Let’s ask ourselves what customers may expect from
Have a look at our «contour-profiled»
CBN grinding wheels video!
further information: www.lach-diamant.de
no. 1, March 2022
9

materials & tools
Automatic profile changing system awarded
At the end of the previous year, Leitz GmbH & Co.
KG was awarded the Innovation Award of the Eastern
Württemberg Chamber of Industry and Commerce –
for the development of the flexTrim3 automatic profile
changing system.
The patented flexTrim3 system was developed specifically
for quick profile changes within continuous production processes
and successfully brought to market. Since its market
launch about two years ago, furniture manufacturers all
over the world have been producing their furniture
components such as carcasses or fronts with this
tool system. FlexTrim3 shows its full effect in batch
size 1 production and leads to significant increases
in the efficiency of the production process by
elimina ting downtimes for profile changes. Since
manual tool changes take a lot of time, this way of
changing profiles is simply uneconomical for batch
size 1 production. Alternative systems for tool
changing are usually very expensive and also require
a lot of installation space within the machine.
The flexTrim3 profile changing system from Leitz;
the name already describes what is probably the greatest
advantage of the system: the combination of three different
profiles in one tool makes edge processing more flexible
than ever before
The product of the world market leader from Oberkochen
convinced and inspired the jury in particular with regard to
the evaluation criteria “economic efficiency”, “originality”,
“chance of realisation and use”, “effort for the idea” and “sustainability”.
The “Award for Patents and Talents” is handed
out every year to regional companies, persons and organisations
for the development and implementation of outstanding
innovative ideas.
With flexTrim3, Leitz offers an economically acceptable
solution for this type of challenge. The
3-in-1 concept allows automatic profile change between
three different profiles. In terms of profile
types, all customer-specific radius and chamfer
profiles, up to a depth of 3 mm, can be implemented
on the profile rims. Even the combination
of “with feed and against feed” is individually possible
with the system. The profile changes are programme-controlled
and take just 30 seconds! The
result is a maximally efficient batch size 1 production
with less manpower and very short downtimes.
The flexTrim3 system is also universally applicable
in the materials to be machined. Softwood, hardwood,
veneer or plastic laminates can be processed
reliably and in top quality. On the machine side, the
new flexTrim3 system can be used specifically on
HOMAG FF32 units.
In terms of sustainability, particular emphasis
was placed on using resources as efficiently as possible.
By using diamond cutting edges, the tools
have very long lifetimes of one year and more before
they need to be replaced. In this way, the pressure
switching mechanism can be reused at the end
of the tool’s lifetime.
flexTrim3 provides more flexibility and efficiency in edge processing
as well as an increase in productivity. A solution from
Leitz showing how practice-oriented and value-added tool
development works today. It proves its innovative strength
and clearly underpins its position as world market leader.
further information: www.leitz.org
10 no. 1, March 2022

materials & tools
Machining carbide with PCD solid
head milling cutters
KNOW THE
FEELING?
With new PCD solid head milling cutters, MAPAL is extending
the possibility of machining carbide and other hard-brittle materials
to smaller diameters.
Deep-drawing dies in the die and mould sector are often made of durable
carbide. Machining them by die-sinking or grinding is tedious. Machining
with coated solid carbide tools often suffers from high wear and low tool
life. PCD tools are a cost-efficient alternative here.
Then stop using complicated
controllers for precision motion.
You shouldn’t need a Ph.D. in
control systems to program your
controller.
The new PCD solid-head milling cutters convince customers
with short process times and long tool lives when machining carbide
and other hard-brittle materials
With Automation1, you can now
reduce your set up time—in
many cases, from days down to
minutes—thanks to a user-friendly,
intuitive interface and machine
setup wizard. Automation1 is the
most user-friendly precision motion
control platform available.
The punches and moulds usually require tools with diameters less than
6 mm. To execute these tool dimensions in PCD, full-head PCD must be
used, since smaller milling cutters have no room for brazed-on cutting edges
and their substructure. With new geometry, number of cutting edges and
arrangement, MAPAL now makes it possible to machine hard-brittle workpiece
materials with diameters from two to six mm.
To produce the perfect PCD tool according to customer requirements,
blanks are kept in stock in the appropriate sizes. PCD is more expensive
than solid carbide, but thanks to the longer tool life and shorter process
times, break-even is quickly reached. In tests, the new milling cutters
managed significantly higher feeds per tooth compared to solid carbide and
therefore a much higher machining volume.
In addition to carbide, hard-brittle materials also include zirconia, a ceramic
material used in dental technology. The new PCD solid head milling
cutters from MAPAL are also an alternative to solid carbide in this area.
further information: www.mapal.com
Motion made easy.
Visit uk.aerotech.com/automation1

materials & tools
Hard, harder, SteelCon ®
More performance in the machining of hardened steel for injection molds
In tool and mold making, the machining of hardened
steels beyond 50 HRC is standard. It nevertheless
remains a discipline for specialists, especially for manu -
facturers of precision tools. The milling cutters used
are subject to very heavy wear. Tool manufacturers
therefore know that long and, above all, process-reliable
tool life is only possible with a coating adapted
to the tool. With the new HiPIMS coating material
SteelCon®, CemeCon now offers the best solution for
this.
Hard machining, especially the machining of injection molds
made of hardened steels with more than 50 HRC, is a demanding
application: the materials are both hard and tough,
and alloying components that increase corrosion resistance
further complicate the machining tasks. “Here the milling
cutters used literally cut their teeth due to enormous feed
rates and high temperatures at cutting speeds of up to 250 m/
min. At the same time, the highest surface qualities are
required even for the smallest contours. In order to machine
as economically as possible under these extreme conditions,
first-class precision tools are required. A prerequisite for this
is the right coating. With our new HiPIMS coating material
SteelCon® we provide the right basis for this,” says Manfred
Weigand, product manager Round Tools at CemeCon.
Perfect combination for top performance
SteelCon® is the second silicon-doped HiPIMS coating
material from CemeCon. While InoxaCon® is excellently
suited for machining stainless steel, titanium and difficultto-machine
materials, the coating experts have developed
SteelCon® specifically for machining hardened steels beyond
50 HRC. Whether dry or wet, milling, drilling, reaming or
threading – SteelCon® is the ideal solution in hard machining
thanks to its outstanding properties.
“The HiPIMS coating material SteelCon® is very wear-resistant,
on the one hand due to its high hardness, and on the
other hand due to its toughness coupled with excellent adhesion.
It has a dense layer structure and the thermal stability
has been increased. Top conditions for best performance!”
emphasizes Manfred Weigand. “Another plus: the wear behavior
of SteelCon® differs significantly from other coatings
available on the market. Tool manufacturers as well as users
are enthusiastic and give us consistently positive feedback:
‘We have never seen such homogeneous wear behavior.’ This
ensures high process stability.”
Since no droplets can form thanks to the HiPIMS process,
SteelCon® is extremely smooth. This means that nothing
stands in the way of optimum chip and heat removal. The
tool can dissipate the heat in the chips, and process stability
increases. Excellent surface qualities are achieved, so that the
user can often save subsequent work – in some cases even the
polishing of their workpieces.
Those who use tools with a matched SteelCon® coating
when machining hardened steels are on the safe side: shorter
machining times, reduced setup and handling procedures,
and better surface quality significantly reduce the bottom
line costs. “We achieve such advantages thanks to the extreme
hardness, high toughness, smooth surface, maximum
adhesion, high thermal stability and dense morphology of
SteelCon®,” says Manfred Weigand in summary.
Tools with a
coordinated
SteelCon® coating
ensure shorter
machining times,
reduced setup
and handling
processes, and
better surface
quality. The
bottom line
is that this
significantly
reduces costs
Whether wet or dry – SteelCon® significantly increases tool life
when milling injection molds made of hardened steels
further information: www.cemecon.de
12 no. 1, March 2022

materials & tools
Slot milling of narrow grooves
Paul Horn GmbH has extended
its circular interpolation system for
slot milling of grooves. Horn offers
the tools in cutting widths from
0.25 mm (0.01") to 1 mm (0.039"),
depending on the diameter.
Depending also on tool diameter, the
maximum milling depth (tmax) is between
1.3 mm (0.051") and 14 mm
(0.551"). Inserts are available with different
coatings to suit the material
being machined. Thanks to its mass,
the solid carbide tool shank ensures
vibration damping throughout the mill
ing process. All variants of tool shank
have an internal coolant supply.
Circluar milling in general
The circular milling system offers users
a host of process advantages: it is fast,
reliable and achieves good surface finish.
During the process, the tool plunges
into the material either at an angle
or horizontally and may then be driven
on a helical path. This means that threads, for example, can be manufactured to a
high level of reproducible quality. When compared to machining using indexable
inserts on larger diameters or solid carbide milling cutters on smaller diameters,
circular interpolation milling is generally more economical. Circular interpolation
milling cutters have a wide range of applications: they are able to machine steel,
special steels, titanium and special alloys. These precision tools are especially well
suited to groove milling, circular interpolation milling, thread milling, T-slot milling
and profile milling.
further information: www.phorn.de
visit us at:
hall 5, stand 5012
Fast, reliable and good surface finish –
the circular milling system from Horn

materials & tools
Plasma etching optimization on complex geometries
made possible by PLATIT’s 3D etch indicator
written by R. Zemlicka, Y. Li, P. Tapp, H. Bolvardi, A. Lümkemann
Wear-resistant hard coatings and cutting-edge
preparation took over key roles
in the optimizations of precision tools. In
addition to the correct selection of the micro
tool geometry, the hard coating must
also be adapted to suit the application [1] .
The best protective hard coating system
could not show its full potential without
fulfilling the basic requirement: sufficient
adhesion to the substrate material. Prior
to the thin film deposition, the substrate
material must be free from any impurities
on the atomic scale. This can be achieved
in high-vacuum PVD systems with glow
discharge techniques igniting a plasma
directly on the substrates and carousel at
several hundred volts prior to the PVD
and/or PECVD process [2 ,3, 4] .
Several inventions were proposed to suppress
the inhomogeneous material removal rate typical
for glow discharge methods [5, 6, 7] . However,
current methods for estimating the etching rate
are insufficient to evaluation the resulting homogeneity, with
limited applica bil ity only on planar substrates [6] . So far, it has
not been possible to reliably evaluate the etching rate for most
critical substrate surfaces such as a cutting edge of the cutting
tools.
The pinion cutter covered with homogenous interference color layer prior to
the etching process and the resulting change of the color after the etching; the
changed colors provide the 3D map of the etching efficiency
figure 2
With this article we would like to introduce our patented
3D plasma etch indicator, which is considered as a breakthrough
in plasma etching profile measurement. This new
approach provides a 3D visual profile of the plasma etching
efficiency over several tens of centimeters of the surface of
any shape with the ability to tailor a dedicated etch profile to
industrial parts of interest.
figure 1
Scale of interference colors of a thin TiO 2 layer with
its corresponding thickness, see literature [8]
To obtain such a 3D etch profile, the studied samples (e.g.,
cutting tools) were covered with thin films reflecting homogenously
a single interference color (e.g., blue). These samples
were then placed into the coating chamber and the plasma
etching procedure was carried out for a defined time. After
plasma etching, the thin inference layer on the sample surface
decreased unevenly in terms of thickness. Since thin film
interference color corresponds directly to its thickness, the
resulting color at any point of the surface provides the information
on the etching efficiency at that particular point with
a resolution of 5 to 10 nanometer.
Figure 1 shows a scale of interference colors of a thin TiO 2
layer with its corresponding thickness reprinted from the literature
[8] . Figure 2 illustrates the usage of the 3D etch indicator
on the pinion cutter. With help of the scale in figure 1, the
color change after etching reveals the reduction of the layer’s
thickness and thus the etching efficiency on the 3D profile of
the substrate.
When using the 3D plasma etch indicator, we found important
information regarding the character of glow discharge
processes, which are finally being used to optimize the coating
adhesion:
1.
It was discovered that the measurement of the etch rate
on the flat test pieces is not relevant for the estimation of
the etch efficiency on industrial samples with 3D geometries.
14 no. 1, March 2022

materials & tools
A) B)
figure 3
joint loading of one drill and two samples of different shapes
A) left, two samples of different shapes coated with homogenous
interference layer; right, samples of the same shape
(and originally the same coating) after the etching process
B) drill before and after the etching process
figure 4
Three tools coated with a homogenous light blue
TiO 2 56 ± 5 nm thick layer and subsequently etched for 10 min;
each tool was etched separately in an argon discharge of
three different parameters
Figure 3 shows on the left the joint loading of one drill,
one triangle shaped test piece and one round shaped test
piece. All three samples were coated with homogenous light
blue layer and underwent together the same plasma etching
procedure.
Figure 3A) on the left shows the homogenous 56 ± 5 nm
thick light blue color layer (see the scale in figure 1) on two
different test samples. The right side of the figures shows the
samples after the etching process. While the dark blue color
in the center of the samples corresponds to the thickness of
38 ± 5 nm, the edges of the samples which were exposed to the
plasma were etched completely.
Figure 3B) shows the condition of the drill before and after
the etching procedure. This tool was etched inhomogeneously.
In addition to the clear material removal gradient from top to
bottom, we can also notice the residual blue color on the cutting
edge, which shows that this crucial part of the tool was
not etched sufficiently.
By comparing the etch profile on the samples and on the
drill surface, we can conclude that flat test pieces are not able
to provide relevant information on the etch efficiency of complex
3D samples. Therefore, the mechanical measurement of
the etch profile of partially covered flat samples cannot be
sufficient and must be replaced by, e.g., our 3D plasma etch
indicator.
2.
We found a way to measure and visualize that different
discharge parameters result in very different distributions
of plasma etching.
While methods using the flat test pieces were able to compare
the etching efficiency of different discharge parameters
on one dimensional scale, we found out that the actual 3D
character of the etch profile differs signifi cantly for different
discharge parameters. Figure 4 shows an example of the
three tools coated with a homogenous light blue 56 ± 5 nm
thick layer and subsequently etched for 10 min. Each tool was
etched separately under different Ar plasma etching conditions,
which we refer to as B), C) and D). Figure 4A) shows
one tool prior the 10 min etching.
The effect of etching with parameters B) is shown in figure
4B). We can see that the interference layer was completely
removed on the cutting edges, however, more than 60 % of
the interference layer remains in the flute and on the drill
land. Such a discharge can sufficiently etch sharp edges, but it
is very ineffective on a flat surface.
Figure 4C) shows more effective etching on the land, but
about 50 % of the interference layer remains in the flute.
The etching with parameters D) shown in figure 4D) shows
a very different etching profile.
Unlike the previous examples, we see the inhomogeneity of
etching from top to bottom. In addition, we see a very different
etch profile when looking at the flute and the cutting
edge. While the flute is etched efficiently, we notice a blue residue
on the cutting edge (see the red circles). This shows that
while we can success fully clean the flute at these parameters,
the most important part – the cutting edge – remains almost
undertreated.
3.
Loading dependency of the material removal rate
by plasma etching.
Our 3D etch indicator showed a significant depen dency of
the etching efficiency on the loading of the tools. While the
etch indicator on Ø 6 mm drills placed in a standard shank
tool hol der showed a relatively high etching efficiency with in
standard etching pro ces ses, micro tools placed in a micro tool
holder showed barely any effect within the identical etching
process. This might be seen as counter-intuitive because we
might expect that micro tools required milder plasma etching
than the Ø 6 mm shank tools.
no. 1, March 2022
15

materials & tools
figure 5
Ø 0.5 mm end mill
source Louis Bélet
This information has significantly helped the development
of a coating process, in particular, for micro tools. A TiSibased
coating was deposited on cemented carbide Ø 0.5 mm
end mill as seen in the figure 5 and tested within wet machining
of titanium alloy at a cutting speed 50 m/min. The
micro tool cutting tests were carried out at Louis Bélet. The
burr heights were measured at regular distances depending
on the machining length.
The graph in the figure 6 shows the result of a dedicated
etching optimization, indicating a much lower burr height for
the micro tool coating with optimized etching compared to
the standard plasma etching generally used for Ø 6 mm shank
tools. While conventional optimization of plasma etching
required feedback from cutting tests for each set of parameters,
with the 3D etch indicator, feedback was visible to the
naked eye immediately after the plasma etch test.
figure 6
Development of burr height as a function of milling length
source Louis Bélet
As a result, the presented 3D plasma etch indicator provides
a tool for selecting the right combination of etch parameters
and provides dedicated etching processes adapted to
the ge ome tries to be coated. This could have never been verified
and adjusted across the PVD industry, even though the
community is aware that the etching process for shank tools
should be different than a gear cutting tool or a segmented
die. In this way, 3D etch profiling can be used to ensure that
the selected etching strategy leads to 100 % treatment of the
sample surface with complex 3D geometry.
Acknowledgement
We would like to thank Louis Bélet for providing us with the
results of the cutting tests.
Literature
[1]
Luemkemann A., et al. (2012)
Schneidkantenpräparation und Beschichtung
XIII. Internationales Oberflächenkolloquium, Chemnitz
[2]
Mattox D. M. (2010)
Handbook of physical vapor deposition (PVD) processing
William Andrew, chapter 13.11.2 – Sputter Cleaning
[3]
Vossen J. L. (1979)
“The preparation of substrates for film deposition
using glow discharge techniques”
Journal of Physics E: Scientific Instruments 12.3: 159
[4]
Chapman B. N. (1980)
Glow discharge processes: sputtering and plasma etching,
Wiley, chapter 7 Plasma etching
[5]
Foller M., et al.
(Aug. 4, 1992)
“Process for
plasma-chemical cleaning
prior to pvd or pecvd
coating”
U.S. patent no. 5,135,775
[6]
Vetter J., et al. (1993)
“Arc-enhanced glow
discharge in vacuum arc
machines”
Surface and coatings
technology, 59.1-3:
152-155
[7]
Cselle, T., et al. (2017)
“Glow Discharge
Apparatus and Method
with Lateral Rotating Arc
Cathodes”
EP2705522 (B1)
[8]
Antończak, A. J., et al.
(2014)
The influence of process
parameters on the
laser-induced coloring
of titanium
Applied Physics A, 115(3),
1003-1013
further information: www.platit.com
16 no. 1, March 2022

materials & tools
Range of carbide rods and
purpose-built solutions
extended
Brings solutions
to the surface.
Boehlerit is a true pioneer in the development
of cutting materials from carbide and a European
premium manufacturer whose outstanding expertise
results from its close links with the steel industry.
The result: high-end grade solutions for rotating
carbide tools that are suitable for a wide range of
applications.
The Kapfenberg-based tool manufacturer looks back on
many years’ experience with regard to carbide blanks and
semi-finished products for the precision tool industry
and offers a multitude of special material grades with varying
grain sizes. Alongside the well-established micro-grain
carbide grades HB10F, HB20F and HB30F, Boehlerit also
offers two grades in the ultrafine-grain range with the
HB20UF and the HB44UF. HB20UF is ideal for the processing
of composites as well as for HSC milling from 60
HRC. HB44UF is used for all rotating tools within the field
of HSC technology and for the machining of hardened
steels up to 62 HRC. HB40T, a special carbide grade that
was developed by Boehlerit, offers a combination of toughness
and wear resistance that is ideal for the roughing of
titanium.
When it comes to milling titanium, its toughness poses
a challenge for the cutting material used, as it leads to high
temperatures and wear levels on the tool blade. To counteract
this, tools require a sophisticated combination of metallic
hard materials that have contradictory properties. Carbide
grade HB40T is the ideal combination of high wear resistance
and toughness. Boehlerit offers the HB40T grade
as a bar material. These blanks are perfect for the manufacturing
of shaft tools of the kind that are used for titanium
roughing applications. The HB40T is thus the starting
point of choice for tooling applications in almost all
indus trial areas where titanium is processed. Typical areas
of application include the processing of aeroplane structure
parts or engine components, products in the medical technology
sector or components for chemical or energy plants.
Boehlerit is also an ideal partner for customised solutions
for pre-formed blanks for milling and drilling tools.
The Boehlerit portfolio also includes the extremely wearresistant
ultrafine-grain HB05UF and the XS10 grade, optimised
for diamond coating. HB05UF constitutes an ideal
solution for the machining of abrasive compound matesrials
as well as for materials within a hardness range of
> 62 HRC. For detailed information and recommendations
see www.boehlerit.com or refer to our catalogue “Carbides
and Semi-Finished Products”.
UGO*
sighted
in
Stuttgart!
grindinghub.de
17.-20.05.2022
Stuttgart
*Unknown Grinding Objects landing in Stuttgart open
up new horizons for the full spectrum of highly innovative
grinding technology and superfinishing. As the new
trade fair at the heart of the market, GrindingHub
presents the complete range: machines, tools and the
entire production environment.
GrindingHub – the new hub of grinding technology.
further information: www.boehlerit.com
Trägerschaft
Sponsorship
Eine Messe des
A Fair by
In Zusammenarbeit mit
In cooperation with

materials & tools
Stable process and improved surface finish
thanks to vibration-damped boring bars
Quality and efficiency in the machining process are
measured using an extremely wide range of parameters.
Naturally, surface quality and process security are
among them. The new vibration-damped boring bars
by Team Cutting Tools from the CERATIZIT Group
ensure that these criteria are met.
These boring bars reliably reduce vibrations and, together
with the flexibility of the brand-new exchangeable head
system, guarantee top quality at a low price.
Uncontrolled vibrations have resulted in the demise of
many an expensive workpiece and reduced efficiency for the
machine operator. But long tool overhangs are often essential
during turning, counterboring or threading so what is the
answer? “Depending on the material to be machined, these
conditions inevitably lead to vibrations that are eventually
transferred to the workpiece, with catastrophic effects on the
surface quality,” explains Christoph Retter, product manager
at Team Cutting Tools from the CERATIZIT Group. “And,
these are not the only limitations for an efficient machining
process – accelerated wear through to tool breakage is also
a factor. At CERATIZIT we are counteracting this with a
new addition to our range, the combination of vibration-damped
boring bars and a flexible exchangeable head
system."
Quiet, drill!
Up until now, machine operators have usually reduced vibrations
by decreasing process parameters such as cutting depth,
cutting speed or feed. “With regards to the highest possible
efficiency, this is only a temporary workaround as the cycle
time often decides whether an order is profitable or not.
The CERATIZIT solution is a newly developed exchangeable
head system, which can be used with base holders, but also
with special boring bars. These effectively minimise irksome
vibrations thanks to the damping system in the tool body,”
explains Christoph Retter.
The result is, that instead of having to reduce the cutting
values, even higher parameters are possible. Machining processes
with long tool overhangs can be completed far more
quickly with vibration-damped boring bars than with those
that are not damped. The damped tools improve the surface
quality in particular and extend tool lives, whilst at the same
time the tool and the machine spindle are under consider -
ably less strain. “This provides for greater sustainability,
as all of the components used last significantly longer. Together
with the cost savings achieved from extended tool life,
the machine operator can now complete even tricky tasks
with an increased sense of calm,” says Christoph Retter.
Thanks to vibration damping, applications are possible
that would not be under normal conditions with minimum
cutting parameters.
The basis for optimised machining with the vibrationdamped
boring bars is the newly developed modular
exchangeable head system from CERATIZIT; with
a selection of eight different exchangeable heads,
it is extremely variable, flexible and versatile
Variable system for a wealth of options
The basis for optimised machining with the vibrationdamped
boring bars is the newly developed modular exchangeable
head system from CERATIZIT. With a selection
of eight different exchangeable heads, it is extremely variable,
flexible and versatile, which will save on purchase and
warehousing costs. Due to the clever positioning of the coolant
nozzle, the exchangeable head system also benefits from
highly efficient cooling and improved chip clearance.
Standard versions of the base holders are available from
CERATIZIT in 200, 218 and 283 mm lengths and diameters
of 25, 32 and 40 mm. “The vibration-damped versions come
in 150, 185 and 225 mm lengths,” says Christoph Retter. Their
strengths include process security, reduced costs per component,
optimum chip clearance and improved surfaces –
and the full benefits can be seen irrespective of the materials
to be machined.
Boring bars: quality not available off the shelf
“These components are without a doubt a highlight from
the brand-new exchangeable head system product range for
turning. The vibration-damped boring bars bring a sense
of peace and calm during machining for both the tool and
user, and the best part is that the costs are manageable and
machine operators won’t need to reach for a stress ball!”
summarises Christoph Retter with a wink.
further information: www.ceratizit.com
18 no. 1, March 2022

Change of management
at Krebs & Riedel
news & facts
For reasons of age, Mr. Jost Riedel (65) retired from the management
of Krebs & Riedel Schleifscheibenfabrik and handed over his function
on February 1 st , 2022, to his brother, Dipl.-Vw. Florian Riedel (53).
Dr. Ingo Kuhl, Jost Riedel, Dipl.-Vw. Florian Riedel
(from left to right).
Jost Riedel worked for Krebs & Riedel for a total of 38 years. Of these, he was a
partner for 36 years and presided over the company as managing director for
24 years. Krebs & Riedel is now headed by Dipl.-Vw. Florian Riedel and Dr.
Ingo Kuhl. Mr. Jost Riedel will remain with the company as a shareholder and
consultant.
Jost Riedel has successfully led the company through numerous crises. Under
his leadership, sales and the size of the company doubled. Future challenges
are mainly the expansion of the site in Bad Karlshafen and the extension of the
national and international sales structures. By arranging the succession in the
management from among the shareholders, the continuity for a successful cooperation
with customers and business partners is ensured. The shareholders and
the employees of Krebs & Riedel thank Jost Riedel for his many years of successful
management and wish him all the best for his retirement.
further information: www.krebs-riedel.de

news & facts
Robot density nearly doubled globally
International Federation of Robotics reports
The use of industrial robots in factories around the
world is accelerating at a high rate: 126 robots per
10,000 employees is the new average of global robot
density in the manufacturing industries – nearly double
the number five years ago (2015: 66 units). This is
according to the 2021 World Robot Report.
By regions, the average robot density in Asia/Australia is 134
units, in Europe 123 units and in the Americas 111 units.
The top 5 most automated countries in the world are: South
Korea, Singapore, Japan, Germany, and Sweden.
e.g. in the cost-efficient production of solar panels and in the
continued transition towards electric vehicles. Several car
manufacturers have announced investments to further equip
their factories for new electric drive car models or to increase
capacity for battery production. These major projects will
create demand for industrial robots in the next few years.
Europe
Europe’s most automated country is Germany – ranking 4 th
worldwide with 371 units. The annual supply had a share of
33 % of total robot sales in Europe 2020 – 38 % of Europe’s
“Robot density is the barometer to track the
degree of automation adoption in the manufacturing
industry around the world,” says
Milton Guerry, president of the International
Federation of Robotics.
Asia
The development of robot density in China is
the most dynamic worldwide: due to the significant
growth of robot installations, the density
rate rose from 49 units in 2015 to 246 units
in 2020. Today, China’s robot density ranks 9 th
globally compared to 25 th just five years ago.
Asia is also the home of the country with the world’s
highest robot density in the manufacturing industry: the Republic
of Korea has held this position since 2010. The country’s
robot density exceeds the global average seven-fold (932
units per 10,000 workers). Robot density had been increasing
by 10 % on average each year since 2015. With its globally
recognized electronics industry and a distinct automotive
industry, the Korean economy is based on the two largest
areas for industrial robots. Singapore takes second place with
a rate of 605 robots per 10,000 employees in 2020. Singapore’s
robot density had been growing by 27 % on average each year
since 2015.
Japan ranked third in the world: in 2020, 390 robots were
installed per 10,000 employees in the manufacturing industry.
Japan is the world’s predominant industrial robot
manufacturer: the production capacity of Japanese suppliers
reached 174,000 units in 2020. Today, Japan’s manufacturers
deliver 45 % of the global robot supply.
North America
Robot density in the United States rose from 176 units in
2015 to 255 units in 2020. The country ranks seventh in the
world – ahead of Chinese Taipei (248 units) and China (246
units). The modernization of domestic production facilities
has boosted robot sales in the United States. The use of
industrial robots also aids to achieve decarbonization targets
operational stock is in Germany. The German robotics industry
is recovering, mainly driven by strong overseas business
rather than by the domestic or European market. Robot demand
in Germany is expected to grow slowly, mainly supported
by demand for low-cost robots in the general industries
and outside traditional manufacturing.
France has a robot density of 194 units (ranking 16 th in the
world), which is well above the global average of 126 robots
and relatively similar compared to other EU countries like
Spain (203 units), Austria (205 units) or The Netherlands (209
units). EU members like Sweden (289 units), Denmark (246
units) or Italy (224 units), have a significantly higher degree
of automation in the manufacturing segment.
As the only G7 country – the UK has a robot density below
the world average of 126 units with 101 units, ranking
24 th . Five years ago, the UK’s robot density was 71 units. The
exodus of foreign labor after Brexit increased the demand for
robots in 2020. This situation is expected to prevail in near
future, the modernization of the UK manufacturing industry
will also be boosted by massive tax incentives, the “superdeduction”:
From April 2021 until March 2023, companies
can claim 130 % of capital allowances as a tax relief for plant
and machinery investments.
further information: www.ifr.org
20 no. 1, March 2022

fairs
news & facts
GrindTec 2022
Groundbreaking innovations and new theme worlds
If not now, then when: after four years the leading
specialist trade fair for grinding technology
is finally getting underway again. From March 15
to 18 more than 300 exhibitors will use GrindTec
2022 to present their innovations to the world
market.
In any case, anticipation for the long-missed live fair
is great – because one thing has been learned and can
also be seen in the active participant numbers: no matter
how professionally digital formats are made, they
can never replace the personal encounter between
two people. But, and we are also aware of this, trade
shows are increasingly being supplemented (and better)
by digital offerings and can thus also help to open up
new markets.
Grinding Match –
the digital way to GrindTec 2022
With its “Grinding Match” platform, GrindTec offers
grinding technology experts worldwide, who otherwise
wouldn’t have any access, the opportunity of visiting
GrindTec 2022. Via this platform there is also the
possibility of actually getting in touch with participating
companies. This should please all exhibitors missing
customers from certain countries. For this purpose
they will be provided with codes by the organizer, helping
their customers to grant access to the trade show.
GrindTec 2022 –
technical and technological highlights
The focus at GrindTec 2022 is clearly on details. It will
map all clusters of grinding and tool grinding technology
in a targeted, precise and comprehensive manner,
without forgetting the upstream and downstream peripheral
areas.
Visitors can also look forward to innovations in the field
of coating technology, trend-setting technologies for cutting
edge preparation or innovative laser processing or tool soldering
systems.
As before, “smart” technologies form the big bracket of
GrindTec. They link the most important processes in grinding
and tool grinding technology with each other. Monitoring
and controlling production technology via smartphone or tablet
is no longer a dream of the future, but it is only possible with
a modern network economy. The manufacturers of machines
and peripheral systems, of process and tool technology have
developed answers to this, which they will present on site.
This can be experienced live at the special show “GrindTec
Factory”: the entire process chain of a tool grinding operation
including the necessary technical interfaces will be installed
close to reality.
PRECISE. POWERFUL. PRODUCTIVE.
kapp-niles.com
further information: www.grindtec.de
Against the background of newly developed grinding
machines, measuring devices, automation solutions, innovations
for the preparation of cooling lubricants as
well as high-precision clamping devices and techniques,
GrindTec offers unlimited potential for unprecedented
impulses and ideas.
Being an important aspect, because the call for fresh
business models and processes is becoming louder in
the industry. Here support can come from a wide range
of innovations from the software sector, which make
the upcoming transformation processes possible in the
first place. At GrindTec, the latest versions of various
user software solutions will be presented, which are indispensable
for the operation and programming of machines,
measuring devices and systems.

news & facts
An excellent 2021 for the italian industry of machine tools,
robotics and automation; also in 2022 a strong growth
The year 2021 was extremely positive for the Italian
industry of machine tools, robotics and automation,
which reported double-digit increases for all key
economic indicators. This trend should continue in
2022, the year when all ground lost in 2020 should be
recovered.
This is in short what was illustrated by Barbara Colombo,
president of UCIMU-SISTEMI PER PRODURRE, the Italian
machine tools, robots and automation systems manufacturers’
association, during the traditional end-of-year press
conference.
As highlighted by the preliminary year’s data processed by
the Studies Dept. & Business Culture of UCIMU-SISTEMI
PER PRODURRE, in 2021 production reached € 6,325 million,
marking a 22.1 % upturn compared with the previous
year.
This is due to the excellent trend of Italian manufacturers’
deliveries to the domestic markets, increased by 27.8 %
to € 2,965 million, as well as to the positive performance of
exports, achieving € 3,360 million, i.e. 17.4 % more than
in the previous year.
Based on the ISTAT data processing by UCIMU, in the
period January-September 2021 (latest available data), Italian
exports of machine tools started to grow again in almost all
countries of destination. Sales to Germany, which turned out
to be the first country for the “Made in Italy” exports of the
sector, went up to € 256 million (+ 38.4 %). The other major
destination countries were the United States, € 251 million
(+ 9.7 %), China, € 154 million (- 5.3 %), Poland, € 118 million
(+29 %) and France, € 117 million (+1.2 %).
The domestic market was extremely lively, as shown by
the data of consumption, which increased by 30.4 % in 2021
compared to 2020, attaining a value of € 4,645 million. The
export/production ratio went down by 2 % points, standing at
53.1 %. In line with the upswing reported by these indicators
was also the growth of turnover, exceeding the value of € 9
billion in 2021, after collapsing to € 7.5 billion in 2020.
Despite the dynamic demand and the improvement in the
context, in 2021 the Italian industry of the sector was not able
to achieve a full recovery after the downturn experienced in
2020 because of the difficulty in sourcing components and
raw materials. This phenomenon caused a delay between the
collection of orders and the actual delivery of machinery.
In particular, according to the survey conducted last
October by the UCIMU Economic Studies Department &
Business Culture on a representative sample of enterprises in
the sector, 95 % of the companies said that there are late supplies.
The average delay is 3 months, which, added to the usual
one and a half months of normal waiting time, makes the
delivery time of supplied components and materials increase
to 4 ¼ months. According to the interviewed enterprises, the
impact of this delay on the delivery time of machinery is estimated
at 4 months. As a result, the average delivery time of
machinery is currently 9 months versus the 5 months, which
manufacturers habitually used to guarantee their customers.
The positive trend reported in 2021 should continue even in
2022, the year when there should be a full recovery from the
collapse due to the outbreak of the pandemic.
further information: www.ucimu.it
Gleason launches LINE in Japan
Gleason Corporation is pleased to announce the release
of its new LINE account, designed to enhance
communications with customers in Japan.
Effective immediately, Gleason now offers customers in
Japan a better way to access news and and communicate
directly with Gleason. The new Line account enhances access
to news on the latest Gleason gear technology developments,
innovative products and services, as well as offering an additional,
direct communications channel for customers’ information
needs. Gleason’s Line account will also give information
on upcoming events, trainings and webinars, and connect
to the popular Gear Trainer Webinar series.
Gleason’s Line account complements the wide array of
Social Media channels and electronic information channels
already provided by Gleason Corporation.
further information: www.gleason.com
22 no. 1, March 2022

news & facts
Nomination for outstanding user and
customer experience
A revolutionary product innovation from the UNITED
GRINDING Group, C.O.R.E. – Customer Oriented
REvolution has been nominated for a UX Design Award
for its outstanding user and customer experience. The
panel selected it from a pool of 300 submissions from
58 countries.
C.O.R.E. from the UNITED
GRINDING Group brings to
life a new machine interaction
concept based on a modern
hardware and software
architecture. It standardizes
op eration of all machine
tools from the UNITED
GRINDING Group, with a
new 24-inch multi-touch
C.O.R.E. panel offering intuitive
controls similar to a
smartphone and personalized
customization options. The
clean design of the C.O.R.E.
panel features only a few buttons,
ensuring clean visuals.
The virtual function keys
are also only displayed when
needed, further reducing complexity and eliminating potential
sources of error. The role-specific interface, with the option
of limiting the display to relevant information for the
user role, also promotes simplification. In this way, C.O.R.E.
improves the working experience both for the machine’s
operators as well as set-up and maintenance personnel.
Another new feature is the integrated front camera, which
enables quick and easy support also via video calls di rectly
from the panel.
The merits of C.O.R.E. also impressed the jury of the UX
Design Awards 2022, earning it a nomination from among
300 products and projects from 58 nations for its convincing
user and customer experience. The award is renowned as the
top global competition for outstanding experiences, presented
by the International Design Center Berlin (IDZ).
Just the beginning
However, C.O.R.E. encompasses much more than revo lu tionary
machine operation. The groundbreaking hardware and
software architecture opens up new possi bil ities for networking,
controlling and monitoring the pro duction process, and
thus for process optimization. It also lays the foundations for
the operation of modern IoT applications and thus opens the
door to the digital future.
further information: www.grinding.ch
no. 1, March 2022
23

news & facts
companies/fairs
EMAG sells EMAG eldec GmbH
as part of a management buy-out (MBO)
EMAG eldec GmbH becomes eldec Induction GmbH. All jobs will be retained.
The previous managing director Thomas Rank takes over the shares of eldec GmbH from the EMAG Group.
Global machine builder EMAG signed a purchase agreement
with eldec induction GmbH under which the EMAG Group
will sell all of its shares in EMAG eldec GmbH. Eldec produces
and sells highly efficient induction heating technology
for a wide range of industrial applications. In addition to
generators for induction heating, the company offers toolmaking
(inductors) and machine tools for induction hardening.
At the EMAG Group, eldec products have been used
in the design of production lines and the construction of
machine tools.
Focus on core business
For the EMAG Group, the sale of the shares is another important
step in the implementation of the EMAG 2025 corporate
strategy, according to managing director Dr. Mathias
Klein: “The aim of our corporate strategy is to further expand
our technological leadership in the machining of rotationally
symmetrical components. We want to achieve this primarily
by using interconnected digital machining systems and with
data analysis to present our customers with the best overall
result.” Commenting on the future of eldec, Dr. Klein explains,
“as a result of the MBO, the transition to an independent
company will take place smoothly, so there will be no restrictions
for existing customers. We will continue to maintain
a close business relationship with eldec, as many products,
such as eldec’s excellent generator technology, are also
used in the systems employed. We wish Mr. Rank and the
eldec company continued success and look forward to joint
projects in the future.”
further information: www.emag.com
33.BI-MU
Focus on five technological issues for five exhibition areas
October 12 to 15, 2022, the exhibition complex of
fieramilano Rho will host 33.BI-MU, the major and
most important Italian exhibition for the industry of
metal cutting, metal forming and additive machine
tools, robots, digital manufacturing and automation
systems, enabling technologies and subcontracting.
Promoted by UCIMU-SISTEMI PER PRODURRE, the
Italian machine tools, robots and automation systems manufacturers’
association, and organised by EFIM-ENTE FIERE
ITALIANE MACCHINE, 33.BI-MU will take place one year
after EMO MILANO, the world trade show of the sector,
achieving resounding success with the public of reference.
Owing to the extremely favourable economic moment,
33-BI-MU will meet the consensus of the enterprises of the
sector. At their disposal is a very dynamic and receptive
Italian market, also thanks to the Government incentives
which remain in force for the whole of 2022.
Willingness to invest in new production technologies, need
for a renewal of industrial plants, which increasingly require
state-of-the-art systems and machines, are the reasons for the
33.BI-MU attraction.
Besides machines and systems, 33.BI-MU focuses on 5
technological issues for 5 exhibition areas representing the
complete ecosystem of the sector: RobotHeart, sponsored
by SIRI (Italian Robotics and Automation Association) and
dedicated to the world of robotics; BI-MU Digital, focused
on the world of ICT and connectivity technologies; BI-MU
ADDITIVE, sponsored by AITA-ITALIAN ASSOCIATION
OF ADDITIVE TECHNOLOGIES and dedicated to additive
technologies; METROLOGY & TESTING centered on systems
and machines for testing, measuring and quality control
and finally, BI-MU LOGISTICS, focused on the logistics for
the mechanical industry.
further information: www.ucimu.it
24 no. 1, March 2022

companies/fairs
news & facts
CHIRON Group and
Greidenweis combine
automation expertise
Carsten Liske, CEO of the CHIRON Group SE, and
Michael Greidenweis, owner and managing director
of Greidenweis Maschinenbau GmbH & Co. KG,
have set the course for a joint future. Greidenweis
Maschinenbau is a 100 % CHIRON Group company
since January 2022.
One of the CHIRON Group’s core competencies is turnkey
solutions for machining processes based on machining and
milling/turning centers of the brands CHIRON, STAMA and
FACTORY5. The demand to automate turnkey solutions is
continu ously increasing, as are the workpiece and industryspecific
customer requirements. This applies to single-part
production in tool manufacturing and precision technology
as well as to series production in the mobility sector. The
CHIRON Group’s product range meets the diverse automation
tasks with integrated automation solutions, autonomous
stand-alone solutions, the linking of machining centers and
their process and system integration in assembly and production
lines.
Greidenweis is a system supplier for the automotive industry.
In addition to its own development and assembly of
machines and systems for laminating, joining and gluing,
Greidenweis has positioned itself competently in process and
system integration. For example the fully automated complete
assembly of components for vehicle interiors using several
processing stations. The 60-employee company has many
years of experience in integrating various technical solutions
into automated assembly systems and production lines,
and has also successfully installed these in other industries.
Greidenweis has developed its expertise in mechanical en-
Successful takeover:
the management teams of the CHIRON Group and
Greidenweis are looking forward to the cooperation;
left: Carsten Liske, CEO of the CHIRON Group SE;
5 th from left: Michael Greidenweis, owner and managing
director of Greidenweis Maschinenbau GmbH & Co. KG
gineering and holistic automation solutions to a high level
through consistently implemented overall process support –
design with CAD/CAM and 3D technology, robot simulations,
project control, manufacturing, assembly, commissioning
and service.
The CHIRON Group and Greidenweis will each concentrate
on the further development of their traditional core
businesses. With the strategic and operational cooperation,
both companies also want to offer their customers attractive,
future-oriented solutions through optimized and new combinations
of products, competencies and know-how. The aim is
to make machining, assembly and production processes even
more efficient with innovative automation solutions. This
applies to the process automation of large-volume components
as well as to complex production lines from the blank
through machining and associated processes to end-of-line
testing.
further information: www.chiron-group.com
GrindingHub
Planning work has started
Over 260 companies had secured a place at
GrindingHub as the registration phase drew to a
close end of September. “We are more than satisfied
with the number of registrations and are delighted
with how GrindingHub is already set to become
the new focal point for grinding technology,” says Dr.
Wilfried Schäfer, executive director of the VDW
(German Machine Tool Builders’ Association).
The strong figures mean that the work can start work on
the layout of three halls at the modern Stuttgart exhibition
center – including the Paul Horn Hall which opened in 2018.
Topical content, contemporary formats and
a highly attractive trade show location
GrindingHub will be celebrating its premiere in Stuttgart
May 17 to 20, 2022. With its international orientation
and an attractive location that is easily accessible
from all over the world, the event holds plenty of potential.
The organizers are also part of a global network of associations
throughout the well-known manufacturing nations,
and have plenty of experience in organizing trade
shows. The principal areas will be technology/processes,
productivity, automation and digitalization in grinding
technology. Two joint “GrindingSolutionPark” booths
are also planned – demonstrating how science and industry
can work hand-in-hand together. The GrindingHub
web sessions will begin in the run-up to the event in spring
2022. These proved their worth during the METAV digital
and will now serve to whet visitors’ appetites for the new
leading trade fair for grinding technology – encouraging to
attend the fair in Stuttgart and meet exhibitors.
further information: www.grindinghub.de
no. 1, March 2022
25

processes
Production systems and manufacturing technologies
for chassis and powertrain of rail vehicles
authors: Manfred Berger, MAG IAS and Leo Schreiber, BOEHRINGER
The European companies of the FFG Group serve
the production companies and maintenance works for
chassis and drive of rail vehicles with optimal products
and manufacturing technologies. A team of successful
specialists with many years of “Rail” industry experience
guarantee high quality and the best economy
with the most modern manufacturing solutions (machine,
technology and peripherals) for the respective
compo nent processing. The systems operate in the area
of maxi mum availability with the appropriate component
and process flexibility for the special tasks. The
design of complete production systems and delivery
of turnkey projects for single and series production by
the system supplier and integration partner MAG as
well as global service coverage with our own technicians
is the key to a high degree of utilization and cost
efficiency. In close cooperation with planning, project
execution and production support, the operator can
use the “Digital Factory” to help shape the successful
implementation.
FFG Group has a complete product portfolio which covers all
processes for the production of prismatic and rotary components
such as: milling, drilling, turning, grinding and gear
cutting for the respective manufacturing task for the chassis
and drive of rail vehicles. The expertise and product portfolio
are available in the individual companies and thus the customer
can be promised an optimal solution for the specific
component processing (figure 1) within the group. The system
supplier MAG (production locations: Germany, Hungary,
USA, India and China) with professional project management
is the coordinator with the competence for factory
planning and supplying of turnkey systems.
1: Individual technology experts for the machining of
chassis components and delivery of turnkey systems
(Bogie: presentation of the company TURBOSQUID)
Chassis frames and large structural components
There are two machine concepts available for the size of a
chassis frame, both of which have a swivel spindle head. The
swivel spindle offers an ideal solution for the structurally restricted
access to the machining point. The gantry type milling
center EVER5 (X / Y / Z: 9,500 / 4,000 / 1,250 mm) from
JOBS (figure 2) with two work areas (fixture nests) on the
table can be loaded and unloaded alternately, parallel to the
main time, without interrupting processing. The traveling
column machine THOR (X / Y / Z: 6,000 / 1,200 / 2,000 mm)
from SACHMAN is equipped with a KOSMO milling
head with a spindle speed of 4,000 rpm. With this solution,
2: Machining of the undercarriage frame (bogie) with
swiveling work spindles on a horizontal milling machining
center THOR from SACHMAN (left) and a
gantry milling center EVER5 from JOBS
workpiece supply can also take place at the same time as the
use of a second W-axis feed unit with an integrated B-axis rotary
table in shuttle mode. The W-axis enables the workpiece
to move towards the tool, particularly in the case of heavy
and high-precision machining, and thus avoids a corresponding
overhang on the tool side by moving out the Z-axis. Both
machines can change the machining heads automatically and
change tools via a sufficiently dimensioned tool magazine for
complete machining of the bogies.
Machining of cubic housing components and
turnkey production systems
The system competence for planning and execution of the
FFG group is represented by the MAG brand. With its own
product portfolio of special machines and CNC machines including
process and equipment for machining, assembly and
measuring stations, system automation (gantry loader or robot)
and purchased systems, MAG supplies individual machines
and production systems for the series production of
housing components, e.g. cylinder blocks, cylinder heads,
26 no. 1, March 2022

processes
3: Production line (pre-machining) for V8 to V20 cylinder
crankcases for automatic series production by MAG with
technology, tools, fixtures and loading gantry
(component: CATERPILLAR Mapleton),
workpiece: max. 4,500 kg raw, 4,100 kg finished
transmission cases, housings for e-drives, as well as complete
turnkey systems for these components, according to the respective
customer specification (figure 3). An experienced
team of project managers is available to coordinate the project
and all co-suppliers. For project execution the latest software
tools for the Digital Factory will be applied, e.g.: for the process
design and optimization of the machining programs the
virtual reality simulation is used. Simulation models are already
created in the mechatronic design phase, with which
virtual commissioning of the products and processes can
be started even before the real system is built (figure 4). In
cooperation with the suppliers of special and peripheral machines
as well as automation, the commissioning of the functions
of a production system can be carried out on a virtual
model without erection of the real units in one common location
and in higher quality, lower costs and shorter delivery
times compared to conventional project management. These
models are also available to the customer as a demonstrator
for training operators and maintenance personnel. In addition
to the digital product twins, the digital process twin for
processing sequence and digital system twin, which optimize
the system for the desired availability and prove it on the
simulation model, are created in the proposal phase.
table:
Assignment of the components to the
respective processing machines
Vertical machining of rotary components
and housings
For the vertical machining of disc-shaped components such
as railway wheels and brake discs, HESSAPP, with its many
years of experience, offers a wide range of process knowledge
for all core processes and optional technologies (ceramic
components, lasers, hardening, grinding) for several
complete series of turning machining centers (table). The
VDM series with sizes 550 to 1,600 mm is used for wheels and
brake discs. With a maximum turning diameter of 1,600 mm
(swinging diameter 1,800 mm), an output of 165 kW and a
payload of 2.5 t, wheels with all material specifications (ER
6 to ER9) – regardless of the area of application of the wheels
(freight, metro or high speed) – can be rough and finish machined
with highest quality on the VDM 1600 machine with
a capacity of 48 tool positions (figure 5). The VDM 1000 machine
is an economical counterpart for smaller wheels with a
turning diameter of up to 1,150 mm.
The DVH 750 turning machining center and the DVT
750 transfer machining center are ideal for self-loading and
pick-up machines of brake discs up to workpiece diameter
of 750 mm. With the integrated workpiece change from the
4: Hardware-in-the-Loop (HiL) – test setup for
virtual commissioning (VIBN) of the digital product twin
5: Power pack VDM 1600 – vertical turning machine for
wheel machining as a manufacturing cell (top right) or
manufacturing system for the production of
ready-to-install wheels (bottom – Lucchini, CAF)
no. 1, March 2022
27

processes
infeed conveyor through the movable work spindle and delivery
of the machined workpiece to the outfeed conveyor,
both machines are more comparable to a production cell
without additional investment in automation. The transfer
machine HESSAPP DVT 750 is a compact vertical turning
cell for two-sided complete machining. With the two turning
spindles, extensive and qualitatively demanding features
can be machined on the workpiece. The technological capabilities
of the HESSAPP DVT 750 thus make it possible to
dispense a subsequent station to complete the processing. A
standing, stationary and a movable, hanging spindle machine
both sides on two workpieces in the machine in parallel operation
and transfer the workpieces without additional equipment
(figure 6).
maximum vibration damping as the basis for the finest surface
quality, extended tool life and thus reduced tool costs.
With the process know-how of the BOEHRINGER turning
specialists, these robust, durable and high-precision
machines produce grinding qualities when required.
The horizontal and vertical CNC lathes of the brands
HESSAPP and BOEHRINGER are intended for integration
in complete production systems (figure 8) and can be ideally
integrated into an automation concept with the interfaces
provided and can be loaded and unloaded fully automatically
from above and from the front. The supply and disposal of
the machines (swarf and suction) can be configured either
centrally or decentralized. For maximum indispensable
6: The unbeatable machine and processing concept of
the HESSAPP DVT 750
Horizontal machining of shafts and axes
The powerful horizontal CNC lathes of the VDF series from
BOEHRINGER are designed for hard machining and highest
component quality. With frame sizes VDF 450 and 650,
all requirements for the wheelset axles and drive shafts can
be covered and the required processes (rough turning, fine
turning, milling, gear cutting and other machining with
driven tools, like drilling, threading, milling) can be covered
(figure 7). The machines are built on hydropol beds for
maxi mum mechanical and thermal stability. This achieves
8: Production plant for ready-to-install drive shafts of
high-speed rail vehicles (turnkey)
availability within an automated manufacturing system, the
accessibility is designed for the shortest service interventions.
The parts and components used meet the high production
demands of a three-shift operation of up to 18/19 shifts per
week with a service life of > 15 years and the permanent machining
accuracy.
The product MORARA MT 2500 HD (figure 9) for sha ft
components with a length of 2,600 mm(3,000; optional)
and a weight of up to 2 t is available from FFG’s Grinding
7: Horizontal lathe BOEHRINGER VDF 450-4 T with a
max. turning length of 3.4 m; main and counter spindle each
with A11 chuck, 2 x 56 kW drive power, 2 x 3,486 Nm @ 40 %
9: MORARA MT 2500 HD CNC grinding machine with
two hydrodynamically mounted grinding units for
complete machining of wheel axles in one clamping
28 no. 1, March 2022

processes
Solutions division for the finest machining of axes and shafts.
The machine is particularly characterized by its productivity
and process flexibility, as well as its high energy efficiency
and compact footprint. Like all FFG machines for integration
in production lines, loading from the front and top can be
carried out fully automatically or manually (stand-alone).
With a maximum grinding diameter of 350 mm and two
grinding units (optional) on high-precision slide and feed
units, driven by linear motors, the axles and drive shafts for
rail vehicles can be finished in one clamping.
The thermal control of all machine assemblies including
the linear drives through their integrated cooling circuits,
ensures the high-precision machining level of the machine
and is supported by the hydrodynamic bearings of the selfbalancing
grinding spindles with a 46 kW drive power (up to
50 m/s circumferential speed of the wheels) and the resulting
long service life. With a B-axis for the right grinding unit,
conical areas on the workpiece can also be machined in the
range +/- 5 ° with a resolution of 0.0001 °.
Turning and gear hobbing wheels and pinions
Vertical lathes of the brands HESSAPP and SMS are suitable
for machining the gearwheels in the powertrain of the
driven vehicles. The gear cutting machines from MODUL H
600 to H 2300 are designed for the series production of large
gears up to m < 28 and workpiece diameters up to 2,400 mm.
The machines can be used for all hobbing and form milling
processes for soft machining as well as for the finished
machining of hardened gears. In addition to spur gears, helical
gears, spherical or conical gears can be manufactured
using hardware and software options as well as shafts with
multiple gears, worm gears and other special profiles. The
MODUL H 600 to H 800 series is loaded with the integrated
ring loader. The larger machines are linked with classic
automation systems (e.g. portal loaders, robots, etc.). In accordance
with the high machining forces and stresses
involved in the manufacture of gears, the large MODULE H
900 to H 2300 series features box ways with coating.
Wheelset machining for maintenance
The machining of vehicle wheelsets for the service is becoming
increasingly important. Recent studies [1, 3, 4] do recommend
the machining of the wheels at each service stop (approx.
70,000 km) with a material removal of 1 mm compared
to the previous condition-based reworking of the profiles
with a material removal of 4 - 5 mm. The elimination of
surface defects in the rolling contact area that begin with fatigue
crack formation are the new approaches to significantly
reduce maintenance costs in connection with a possible
doubling of the service life to up to km 1.6 million mileage [2] .
In addition to special machines for turning wheelsets in an
installed (underfloor lathes) or removed (above-floor gantry
machines) condition, CNC lathes such as the BOEHRINGER
VDF DUS 800/1000/1110 (turning length 820 to 1,110 mm
above bed, figure 10) up to size VDF 1300/1500/1600 DUS
(1,300 to 1,600 mm above bed) are also available for the repair
shop for smaller series. A highlight of the series are the hardened
double prism guides with scraped guide surfaces on the
slide, which are the basis for the high and durable machining
accuracy and highly economical production.
10: Horizontal CNC lathe BOEHRINGER VDF 1110 DUS for
machining wheelsets for profiling the wheels and
machining the brake disc surfaces
FFG Group offers itself as an ideal partner with the wide
range of manufacturing machines for different technologies
in the area of drives and running gear for rail vehicles. Due
to the turnkey system competence, peripheral systems up to
complete production plants can be planned and handled. In
close cooperation with the plant operator, the appropriate
technologies from the partly overlapping product portfolio
are selected in the planning phase, taking customer preference
into account, and the most cost-effective solution for
high productivity is worked out with regard to the required
flexibility of the technologies, component bandwidth and
production volume. With globally available efficient service
and a special memorable training program for operators
and maintenance personnel, the robust and durable products
unfold their full efficiency using the latest technologies.
References
[1]
Boudnitski, G., Edel, K.-O.:
Oberflächendefekte im Scheibenbereich,
Abschlussbericht zum DFG-Projekt,
Brandenburg an der Havel, April 1998
[2]
Müller, R. et al.:
Definition on wheel mainenance measures for reducing
ground ibration,
EU FP7 project RIVAS, SCPO-GA-2010-265754,
November 2013
[3]
Alstom:
Technical specification wheel wear analysis,
CCN-WR-Analysis, December 22, 2003
[4]
Muhamedsalih, Y., Stow, J., Bevan, A.:
Use of railway wheel and damage predicitions tools to improve
maintenance efficiency through the use of economic
tyre turning (ETT),
Institute of Railway Research, University of Huddersfield,
UK; in: Journal of Rail and Rapid Transit, July 2010
further information: www.mag-ais.com
no. 1, March 2022
29

processes
Intelligent generating grinding – quality assurance
for e-transmission gears already on board
Transmissions for electric cars are much simpler
in design than for conventional combustion engines,
but place far higher demands on the manufacturing
precision of the gears used. Thanks to completely new
procedures for quality assurance directly in the final
machining process, which is gear grinding, these specifications
can also be met in series production.
All-electric vehicle drives usually make do with two-stage,
non-shiftable transmissions. One would have thought that
this would greatly simplify production. After all, this type of
transmission design has just four gears, distributed between
the drive shaft, the second stage with fixed gear and intermediate
shaft, and the axle drive gear. But in reality, it’s not that
simple: first of all, engine speeds are much higher for the e-
drive than for combustion engines, at up to 16,000 rpm. This
means electric motors deliver an almost constant torque over
a wide speed range. Unlike combustion engines, it is applied
to the transmission right from zero speed.
Furthermore, there is an additional constraint that makes
production much more demanding than with the conventional
drive train, as Friedrich Wölfel, head of machine sales
at Kapp Niles, describes: “The noise from a combustion engine
masks the transmission noise, meaning it is not noticed
in the first place. On the other hand, an electric motor
is almost silent. Above about 80 km/h, rolling noise and wind
noise are the predominant sounds, irrespective of the drivetrain.
But below that speed, transmission noise can be irritating
in electric vehicles. We also have to take that into account
when manufacturing gears.”
Of course, the flank load capacity of the gears and good
running properties are also of paramount importance with
e-drives. However, the almost constant torque level and the
high speeds require a different gearing design, which in turn
can affect the noise dynamics. Here, in particular, demands
are higher than with combustion engines.
However, when it comes to the pressure to generate maximum
efficiency, there is no difference at all between gears for
e-vehicles and conventional drives. Accordingly, the highly
productive generating grinding process is also generally used
as a fine machining process in the series production of e-
transmission gears.
The challenge for Kapp Niles, as a specialist in hard fine
machining of gears, is to implement a generating grinding
process that is both productive and, above all, optimised in
terms of noise dynamics.
Hot on the heels of transmission noises
Achim Stegner, head of predevelopment at Kapp Niles,
describes the basics: “Depending on the modifications of
the gearing defined at design stage, such as line corrections,
width convexity, head retraction, as well as the profile and
line interlocks typical of the process, characteristic noises
occur in the transmission during meshing, which can be
30 no. 1, March 2022

processes
figure 1
Tolerance corridors for closed loop
assigned to specific tooth meshing frequencies. The entire
transmission, in turn, also exhibits characteristic properties
with regard to structure-borne noise and radiation, depending
on the constructive design. This is stimulated in the tooth
meshing frequency and its multiples. Manufacturers try
to minimise this effect as much as possible by adapting the
design of transmission and gears.”
For the time being, these considerations only apply to “perfect”
gearing. But of course, like any other mechanical component,
gears also generate variances from the ideal target
geo metry in series production. These have different causes
and effects, as Achim Stegner explains: “In addition to the
stimulation caused by the tooth mesh, there are other disturbance
variables that can result in noises in the tooth mesh.
These make themselves felt as ‘ghost frequencies’. These are
frequencies that do not coincide with the tooth meshing frequencies
and their multiples, and can just be introduced
into the component during grinding.” Ghost frequencies are
caused by minimal irregularities that are almost impossible
to completely avoid in series production. It becomes particularly
critical when these variances map almost exactly onto
the circumference of a gear, as this results in harmonic stimulation.
It takes a lot of expertise and process experience to
recognise the reasons for such irregularities and, if possible,
to avoid them in the first place.
The cause of such malfunctions can be found, for example,
in the axis drives of the machine tool used. Electric motors
have certain pendulum moments. Measuring systems work
with discrete line counts and finite eccentricity errors from
assembly. Last but not least, balance condition and spindle
bearings can contribute to possible irregularities. Waviness as
small as 0.1 mm can cause noise in gears. Achim Stegner explains
some more causes: “Every machine has natural vibrations.
For example, the typical natural frequency of a workpiece
spindle is about 250 Hz. This can also be reproduced
exactly on the workpiece if the speed constellation in the generating
grinding process is unfavourable. We can eliminate
such effects by the clever choice of a suitable speed window
during machining.”
Once the optimisation potential on the machine side has
been exhausted, there are also a number of technological
options for improving component quality in terms of noise
dynamics. These include, for example, the selection of the
number of gears of the grinding worm, the speed ratio during
dressing and grinding, the finishing speed and the feed rate.
Not all errors are the same
Roughly speaking, there are two typical types of error patterns
in serial gear grinding: on the one hand, trends are
emerging that show a continuous change in characteristics.
On the other hand, there are individually conspicuous components.
Trends are usually easier to control. They can be
caused, for example, by the gradual wear of a grinding worm.
If permissible manufacturing tolerances are exceeded here, it
is usually sufficient to shorten the cycle between two dressing
processes. They can also be easily recognised during component
testing by a gradual approach of the measured values to
the tolerance limit.
Component-specific defects, on the other hand, are unpredictable.
They become noticeable through sudden deviations
in one or even several quality criteria. This can be caused by
grinding worm chipping, workpiece blank errors or set-up
errors.
Since the actual machining of a gear takes much less time
than the control measurement in highly efficient manufacturing
processes such as generating grinding, it is also not
possible to inspect every single component. In addition, as
no. 1, March 2022
31

processes
described at the beginning, quality demands for gears for
e-transmissions are extremely high. “The required tolerances
of profile angle, flank line angle, concentricity, two-ball dimension
are in some cases smaller than in the conventional
drive train by a factor of 3. For the flank line angle error
fHß, a typical requirement is ± 4 mm; with combustion engine
transmissions, this was sometimes ± 13 mm,” says Friedrich
Wölfel, describing the requirements of his customers.
Together with the required machine and process capabilities,
these quality requirements are testing the limits of what
is technically and economically feasible. And the static and
dynamic stability of the processing machine and process cannot
be increased at will. The only way out is to start with the
methods of analysis and control. Because otherwise: the narrower
the tolerance limits become with the same machine/
process capability, the greater the number of measured components
must be. However, this involves a great deal of effort.
And ultimately, downstream component testing does not add
value either.
With regard to the approach to trend-related deviations
from the target geometry in particular, the ‘closed loop’ has
already established itself as an important tool. This accelerates
and improves the feedback between downstream gear
measurement and the processing machine itself. Here the results
of the inspection on the measuring machine are no longer
printed out and made available to the machine operator
on paper for evaluation, but are transmitted directly to
the processing machine as a standardised file. The grinding
machine then uses preselectable tolerance corridors to decide
independently whether it needs to intervene in the process
at all, for example with scalable correction values. If unexpectedly
high variances from the target geometry occur,
the decision on how to proceed is then up to the operator
themselves (figure 1).
The referee at the end of the
manufacturing process
At the end of the manufacturing process of a complete transmission
is what is known as an ‘end-of-line test bench’. It is
no longer just individual gears that are tested here with regard
to their quality, but fully assembled transmissions are
evaluated. They go through various test cycles that simulate
operating conditions in an actual vehicle. The operating noise
is also recorded. Acousticians can analyse this data to extract
intervention ratios, typical frequencies and possible interfering
noises. “Unfortunately, this also means that gearing defects
are only noticed at the end of the manufacturing process,”
complains Friedrich Wölfel. “The complete transmission
must then be dismantled, the individual components
checked and, based on this, analysed to determine which
component is responsible for the anomaly on the test bench.
It could also be that a complete batch of components can
cause problems. But that only becomes apparent when the
entire value chain has already been completed.”
Today it is possible to identify components that could cause
noise before they are installed in the transmission. A very
common procedure for e-drives is the waviness analysis on
gear surfaces. Here, profile, line and pitch measurements are
carried out on all teeth on the gear measuring machine and
lined up in such a way that the gear is mapped over its complete
circumference. The waviness on the gear wheel can be
mathematically measured. However, starting with the complete
measurement of the gears, this procedure is very timeconsuming
and thus unsuitable for testing every single piece
in series production. Friedrich Wölfel on this: “The grinding
time of typical e-transmission components is less than
one minute, whereas the measuring time is four to six minutes;
indeed, in the case of an all-tooth measurement as the
basis of a waviness analysis, it can be significantly more. And
ultimately, downstream component testing does not add
value either. What is needed here is further development of
in-process analysis, which allows conclusions to be drawn
about the component quality produced during the machining
itself.”
Identify possible noise problems
at the machining stage
A promising approach is indeed to detect possible defects as
early as the grinding process. Process monitoring is the buzzword.
Achim Stegner explains the approach: “We already
have numerous sensors and measuring systems in the machine
that can provide us with many indications, measured
values and information. At the moment, we primarily use it
only to operate the functions of the machine. In the future,
however, we also want to use it to assess the machining process
directly in the machine.”
figure 2
Error analysis and index calculation in the machining process
32 no. 1, March 2022

processes
However, this does not mean integrating
an additional tactile measuring
function into the grinding machine
in order to achieve a faster closed loop.
Nor is it a question here of inspecting a
ground component directly in the machine,
evaluating it and correcting any
discrepancies during the production of
further components. The focus is rather
on analysing the machining process
in real time (!) in order to detect deviations
from a previously defined reference
process. However, it is not enough
to only define envelopes for signals
from the machine to do this. This can
be explained using the “power consumption
of the grinding spindle” signal
in figure 2 as an example. This signal
can be used to detect a possible
flank line angle error (fHß) at an early
stage. Stegner: “However, the procedure
via envelope detection reaches its limits
here, as the error is difficult to iden -
tify. As long as the signal remains within
the envelope, no alarm gets triggered.
So you need a more intelligent form of
evaluation. An artificial intelligence
that attempts to emulate human decision-making
structures. This involves
making decisions based on a multitude
of different information – overlaid with
the person’s own experiences – upon
which they act.
Process monitoring:
intervene before it’s too late
Process monitoring can be defined as
component-specific monitoring and
evaluation of the grinding process. As
described, it is not a trivial matter to
generate an action instruction from the
sensor signals. But it is possible. Various
characteristic values can be formed
from time signals. In the simplest case,
these can be maximum or RMS (root
mean square) values of the signals. The
characteristic values are then combined
with the known project data via algorithms
and processed into indices, for
example a noise or screw breakout index.
Achim Stegner explains about trans -
mission noises specifically: “An order
analysis similar to the order spectrum
on an end-of-line test rig can be created
for noise-critical components via an
FFT (fast fourier transformation). This
makes it easier to classify the recorded
signals and relate them to results on the
transmission test bench (see figure 3).
figure 3
Order spectrum, recorded on a transmission test bench
Measurement data that is not processed is of no use.” In the end, especially in the
manufacturing environment, only appropriate indices help to identify errors very
specifically.
The benefits of process monitoring can therefore be seen
in the following points:
→ 100 % testing of all components
→ identification of anomalies while still in the grinding process
→ detection of component-specific faults
→ targeted reporting of irregularities
→ adaptive intervention in the process
→ parts tracing
Next step: standardisation
Process monitoring is not yet an app that you can simply download and use.
Rather, it is a customer- and application-specific development that defines and
monitors indices in relation to the respective component. But even this first step is
far more than was considered feasible until only recently. Achim Stegner on this:
“Several pilot customers are already using this functionality today. We are already
able to detect different errors and intervene on the process side. In addition, we are
already working on having the grinding machine teach itself characteristic values
for new components. However, this of course requires broad empirical knowledge
from error patterns, the geometric quality of the components and corresponding
feedback from the transmission test bench.” Friedrich Wölfel adds:
“The next goal is that the user can also use this functionality without our component-specific
support. It is also important to understand that process monitoring
and closed loop are not contradictory, but complementary.”
Both approaches to process-integrated quality assurance are already available
for Kapp Niles machines today and are continuously being given further functional
scopes and utilisation options through the experience gained from series
production.
further information: www.kapp-niles.com
no. 1, March 2022
33

processes
Flexibility, transparency and cost savings
BMR elektrischer und elektronischer
Gerätebau GmbH is now presenting
MotorView to the trade public for the first
time at GrindTec 2022.
This measuring system can very sensitively record
the current load status of converter and
motor in a drive system and display it graphically
and numerically on its separate display.
As usual with BMR, the focus is on easy operation
and installation. MotorView is simply
“looped” into the motor cable between the inverter
and the spindle. This makes it possible
to use and retrofit the measuring system in any
grinding machine with a
converter-motor
combination up
to 400 V voltage
and 20 A
current.
MotorView
can be used
to graphically
display and
monitor the
grinding process
as well as
to control the
efficiency of
the converterspindle
unit.
Depending on
the version, it
provides precise
data on the voltage
and current of the
individual motor
phases as well as the
current rotational frequencies.
This enables the machine operator to detect,
for example, whether his system is poorly parameterized,
control oscillations are occurring
or the spindle is being operated with a voltage
that is too high for the currently set speed. This
saves operating costs and prevents possible failures
due to maintenance or tool damage.
As an interface to machine control the
same digital and analog inputs and outputs
are available as with the DressView dressing
system. This has already been presented by BMR
in 2018 at GrindTec and has since proven itself
in practice in many applications. It remains
the only system on the market worldwide that
enables sensorless grinding and dressing from
a single source.
Furthermore, two newly developed frequency
converters await visitors at the BMR-booth.
SFU 1000 for small and medium-sized milling
and grinding machines as well as for all CAD/
CAM systems with high-speed drives. With
an increased output current of 12 A, it can also
drive larger spindles with higher current requirements
and this at 55 V ac output voltage.
With a very compact size, comparable to a
cigarette box, the SFU 400 can drive AC and
BLDC motors at speeds up to 100,000 rpm. It is
of particular interest to manufacturers of CAD
machines or spindles in the miniature range,
and can be accommodated in any housing and
application.
GrindTec 2022, hall 1, booth 1067
further information: www.bmr-gmbh.de
34 no. 1, March 2022

processes
CNC chamfering
The ideal process for every need
Chamfering gears prevents the edges of the teeth
from becoming brittle during heat treatment and
reduces transportation and installation damage. Multiple
processes can be chosen for this. Classic technology
such as press deburring or chamfering with end
mills are increasingly being superseded by CNC controlled
processes such as ChamferCut and FlexChamfer.
These are extraordinarily economical and guarantee
an excellent chamfer quality which can be reproduced
very precisely. CNC controlled processes are
easy to operate and minimize set up cost.
Liebherr knows the advantages and the limits for the various
processes and individually advises customers with their selection.
Requirements for an optimal chamfering process can
be individually arranged by batch size, chamfer shape, subsequent
machining or component geometry. Liebherr specializes
in particular in the ChamferCut technology from
LMT-Fette. As a pioneer in introducing this process and its
development to being production-ready, Liebherr is determined
to take this further in the future: by consulting with
clients, both companies are working to improve precision,
productivity and usability.
ChamferCut –
precise, quick and reliable
◆ precise chamfering geometry and quality,
no material deformation
◆ can be reproduced very precisely
◆ easy operation, short setup times due to CNC control system
◆ single-cut strategy: no additional finishing cut
required to remove bulging on the lead
◆ low investment cost and long tool life
◆ ideal for subsequent finish machining
◆ integrated chamfering device or standalone
machines from Liebherr enable parallel machining
◆ application range module 0.5 - 36 mm
ChamferCut CG (collision gear) –
chamfering despite interfering contour
◆ deburring the tooth space to the tooth root surface,
even on interfering contours chamfering including
the root, even for collision critical
◆ more degrees of freedom with the chamfer divided
between the left and right profile
◆ can be implemented on Liebherr machines
with a simple software update
◆ batch sizes: suitable for medium and
large-scale production
→ application examples:
truck shafts, passenger vehicle idle gears and
ring gears, industrial gearboxes
ChamferCut
ChamferCut IG (internal gear) –
chamfering of internal gears
◆ chamfering of internal gears on both flanks in one cut
◆ machining on compact standalone machine, e.g. LD 180 C
→ application examples:
internal gears of plantenary and e-motive gearboxes
FlexChamfer –
maximum flexibility for external and internal gears
◆ CNC controlled advanced development of
chamfering with end mills
◆ development of variable chamfering forms
with standard catalog tools
◆ particularly suitable for external gears with or
without interfering contours as well as
shafts and internal gears
◆ use in hobbing, shaping and gear skiving machines
◆ parallel to machining (depending on the
main machining time)
◆ ideal for small and medium batch sizes
→ examples of use:
stage planetary gears, double internal gears
further information: www.liebherr.com
no. 1, March 2022
35

machining center
Tornos: a source of strength to
medical device manufacturers around the world
Few industries are as regulated – or as associated –
with the need for quality, safety and transparency, as
the global medical device manufacturing sector. And
no partner is more committed to advancing medical
device and instrument manufacturers’ precision,
quality and return on investment than Tornos. For
more than 30 years Tornos has closely collaborated
with medical device manufacturers worldwide to
help them deliver impeccable products that improve
patients’ quality of life. The company’s medtech leadership
was underscored this autumn when MEDTECH
OUTLOOK magazine named Tornos as a recipient
of its Top Medical Device Manufacturing Companies
in Europe 2021 award. The annual listing honors ten
companies at the forefront of providing medical device
manufacturing and impacting the industry.
Headquartered in Switzerland and boasting a global footprint,
automatic turning machine manufacturer Tornos
is a pioneer of sliding headstock technology or Swiss-type
automatic lathes. Because the high-precision turning sector
is subject to stringent standards governing quality, precision
and productivity, it is little surprise that these Swiss strengths
come from the same part of the world.
SwissNano for flawless dental applications
Tornos’ SwissNano is the champion for manufacturing
small – even micro – medical and dental parts requiring very
high precision. The machine’s unique kinematics enable turn -
ing, drilling, cutting, deburring, roughing and finishing
operations for the tiniest parts, whether simple or extremely
complex. Behind the SwissNano is a machine concept delivering
exemplary balance and thermal management allowing
perfect results. This compact solution offers excellent accessibility
for easy setup and can be used with a fixed/rotating
guide bush – or no guide bush at all.
With all those attributes – as well as superb energy efficiency
that boosts its sustainability profile – it’s no wonder
the global dental implants manufacturing leader this year
purchased 45 SwissNano 7 machines for installation in its
plants in Brazil, the United States and Switzerland.
“The SwissNano 7 was chosen because of its precision,
quality, return on investment, and our experience throughout
the medtech value chain,” says Tornos CEO Michael Hauser.
Vast experience throughout the medtech production
chain, a holistic approach, a complete production
program and a global presence make Tornos the perfect
partner to medical device and instrument manufacturers
and their suppliers.
Moreover, thanks to experience across a broad range
of industry segments – including medical & dental,
automotive, micromechanics, and electronics – Tornos is
uniquely positioned to partner with manufacturers, offering
them support to deal with increasing product complexity,
for example.
Tornos offers manufacturers professional,
specialist solutions in the very demanding field
of medtech. To meet the industry’s needs, major
technical advances are required. Tornos
relies on its own technologies, quality, and
medical & dental experience to create solutions
that keep manufacturers at the frontier of medtech
innovation.
Tornos’ solutions for medical & dental range from the
micro- and nano-precision Swiss-type SwissNano for
dental applications such as implants and abutments; the
Swiss-type SwissDECO for production of orthopedic nails;
and the MultiSwiss multispindle machine solution for manufacturing
long locking parts and screws for spine surgery.
Tornos’ mastery
of Swiss-type lathe
kinematics ensures
the flawless results dental
implant manufacturers expect
36 no. 1, March 2022

machining center
Tornos chief sales officer (CSO) Jens Thing further detailed
the SwissNano 7’s direct benefits to manufacturers in the
medical & dental sector.
“Because the production of dental applications such as
implants and abutments is subject to stringent standards
governing quality, precision, and productivity, this model
Swiss-type machine was selected. Behind the SwissNano
series is a machine concept delivering exemplary balance and
thermal management,” he says. “Our customer is able to
boost productivity, reduce its costs per part, and produce
perfect parts.”
SwissDECO and
MultiSwiss for perfect implants
When it comes to implants – whether for dentistry or orthopedics
– Tornos’ SwissDECO and MultiSwiss platforms
deliver peerless productivity and quality.
The multitasking SwissDECO range represents Tornos’
vision of the future of the Swiss-type lathe. Its enhanced
machining and tooling solutions make it superb for medtech
applications. The compact SwissDECO enables highly productive,
extremely precise and high-quality production of
complex parts, thanks to its optimized programming tools
and ideal ergonomics to speed up parts programming and
shorten machine preparation and setup.
Tornos has
vast knowledge in the production
of cancellous, cannulated and cortical bone screws
At the same time, Tornos’ MultiSwiss platform makes it
possible for manufacturers to quintuple their productivity
and secure their position in medtech. From screws for facial
surgery and spinal fusion to various implants, the easy-touse
MultiSwiss consumes minimal floor space and boasts
less tool wear and better surface finish than comparable solutions
– all while allowing quicker reaction times, unique
homogeneity of production results, and fast setup due to
unique accessibility. In this way manufacturers can boost
their productivity, reduce their costs per part, and produce
perfect parts.
Tornos’ solutions for
medical & dental: SwissDECO
further information: www.tornos.com
no. 1, March 2022
37

machining center
Future of tool grinding
“Dear tool grinders, don’t say later
that you didn’t know”
Only someone who is completely convinced of his
new tool grinding machine is that confident when he
speaks. Dirk Wember, managing director of Haas
Schleifmaschinen in Trossingen, Germany, has revealed
some interesting details about the new hightech
tool grinding machine. “With the new Multigrind®
Radical we’re making an offer to the industry
to change the way we’ve been working and enter the
future of tool grinding."
As Dirk Wember reported, customers have been asking for
years: please develop a high-tech grinding machine that is
focused consequently on tool grinding. Until now, the Multigrind®
CU was available in the portfolio. However, this hightech
solution was intended for complex tools and not explicitly
for fast, simple series production. For many customers,
the universal grinding machine was simply too versatile. “On
our Multigrind® CU, we now grind extremely complex freeform
shapes, including medical products or gears. Of course,
it is also possible to grind the absolutely perfect profile insert,
or the perfect tap on the Multigrind® CU,” says Dirk Wember.
New requirements demand a new fiction
The requirements for the production of precision tools have
grown significantly in recent years. The buzzwords here are:
more precise tools, just-in-time production, lower quantities,
very small batches from batch size 1 to 100, chaotic assembly
and faster production. This significantly increases competitive
pressure and requires greater flexibility in tool grinding
with minimal non-productive time. A perfect fit for a hightech
machine concept that leaves the beaten track behind.
The designers and software developers at Haas
Schleifmaschinen have said goodbye to all existing solutions
on the market and have radically rethought their tool grinding
machine and then realized it rigorously. Since the end
of last year, there have been repeated indications that Haas
Schleifmaschinen has developed a promising machine. And
expectations among tool grinders are correspondingly high.
“Anyone who knows Haas Schleifmaschinen knows
we only develop something new if we can
radically improve what we already have”
“And better doesn’t just mean faster, easier, more flexible,
more economical and more precise than comparable tool
grinding machines. At the end of the day, these are just results.
We want to transform tool manufacturing with our Multigrind®
Radical,
so it’s not
about better,
we’re starting
a change. Of
course, this is
not done with
The new Multigrind® Radical:
the game changer for all tool grinders
one machine
alone. We have
developed the basics for the game changer in our own software
department. The perfect choreography between software
and hardware is crucial. And we have succeeded excellently
in this.”
Haas Schleifmaschinen is not a traditional grinding
machine manufacturer. For around 30 years, the high-tech
machines have been operated using the company’s own
Multigrind® Horizon software. New applications and updates
are constantly being added to increase both productivity and
precision. With the innovative Multigrind® Styx visualization
software, grinding processes are optimized before production
starts. At Haas Schleifmaschinen, software developers
meet machine experts and customer experts meet an ambitious
management team. This is what makes technology
leaders work and creates the best conditions for a comprehensive
range of solutions.
“Check your ambitions,
and don’t let the future slip away”
All in one: the machine
The Multigrind® Radical is an “all in one” machine, but not
a universal grinding machine. It was explicitly developed
for the future of tool grinding. According to Wember there
are no limits to this. Maximum precision for both rotary
and plate tools. This means that all customer requirements
can be produced extremely flexibly on just one tool grinding
machine in the future. Milling cutters, inserts and drills
are ground via a chaotic loading system, as required. In large
quantities or as very small series from batch size 1 to 1,000.
On a small scale: very big
The Multigrind® Radical bridges the gap between opposites:
the new tool grinding machine is on the one hand maxi -
mally equipped and yet radically reduced. It stands rocksolid
on a minimal footprint and is ideally suited for a low
hall height. The machine bed is inherently rigid and made
38 no. 1, March 2022

machining center
All in one: cutters, inserts, drills – all on one tool grinding machine
of mineral casting. This makes the new Multigrind® Radical
a small solo and space artist. Or a super productive production
cluster with very low space requirements. Large production
volumes and mixed jobs can be handled simultaneously
with several Multigrind® Radicals extremely quickly and
efficiently.
Radical: faster
According to Dirk Wember, the Multigrind® Radical is radically
fast and very efficient. Best times for both tool change
and wheel change have been announced. The parallel tool
and grinding wheel change saves additional time. Apart from
this non-productive times are consistently reduced. The announced
increase in productivity will set new standards.
And! the new Schnell will be very easy to handle.
Mission: control
A new innovative operating concept is also set to provide a
surprise. Haas Schleifmaschinen is talking here about decoupling
operation from the machine. According to Haas
Schleifmaschinen, the machine operator is mobile and always
up to date everywhere. Fully automated, unmanned series
production becomes the production standard with the Multigrind®
Radical. Haas is also going its own way with its operating
concept and here, too, two opposites are combined:
freedom and maximum control.
Simply: get started
The software developers have done a great job. The very fast
integration into the production succeeds without much
programming effort. Production starts immediately and
without loss of time. Haas Schleifmaschinen promises no
lengthy training during setup and operation. Programming
is simple and makes very fast production changes possible.
What’s more, Haas precision is uncompromising. With
the Multigrind® Radical, there is no compromise on value,
quality and precision. “This is our brand essence, we make
no compromises here.” emphasizes Dirk Wember.
Simply: the new fast
“Simplify your work” with Multigrind® Horizon software, the
Multigrind Radical is immediately ready for production. Parameterization,
templates and ERP information form the data
basis. No control is necessary. Just provide parts and start.
Cloudgrinding
“Cloudgrinding” is another buzzword behind which real
added value is hidden. The machine control is located in the
customer’s corporate network, the added value comes from
the cloud. Additional performance service, current updates,
physical information, safety instructions, process parameters
can be easily retrieved from the cloud on request. So all
additional information is available without time delay. Secure,
certified and pay per use. In other words, only when the
added value is actually needed. The Multigrind® Radical will
definitely be a topic at the leading trade fair GrindTec.
GrindTec 2022, hall 7, booth 7014
further information: www.multigrind.com
no. 1, March 2022
39

machining center
The latest grinding machine development
with an innovative machine concept
WALTER is introducing its
latest addition to the machine
range portfolio at the exhibition
GrindingHub 2022 in
Stuttgart, Germany from May
17-20 th in hall 9 stand A50:
The HELITRONIC G 200
tool grinder with innovative
machine concept on a small
footprint.
On a floor space of less than 2,3 m 3
the cost-efficient HELITRONIC
G 200 offers tool grinding at its
best: production and re-sharpening
of rotationally symmetrical
tools in the diameter range
of 1 to 125 mm, with a maximum
tool length of 235 mm and a
The Top loader offers automation without increasing the foot print of the machine
tool weight up to 12 kg. Maximum grinding wheel
diameter is 150 mm.
The ergonomic design and the integrated and
swivelling multifunction touch panel with a 21.5”
monitor facilitates the operation and accessibility
of the working area. A low-vibration solid mineral
cast bed and the C-frame construction offers high
damping capabilities and temperature stability
resulting in maximum precision in grinding. The
linear axes X, Y, Z are built according to the high
WALTER quality standard. The rotating A- and
C-axes are equipped with torque motors and provide
an unprecedented lifetime with minimum
service effort. For maximum flexibility, a loading
system is available: The “top loader” is directly
integrated into the working envelope of the machine
for easy access and therefore requires no additional
space. Suitable for tools from diameter 3 mm
to 16 mm, the maximum tool capacity of the loading
system is for example 500 tools at a diameter of
3 mm. The top loader uses WALTER-standard robot
pallets and automated electrical teaching.
The HELITRONIC G 200 uses the worldwide pro -
ven grinding software HELITRONIC TOOL STUDIO
from WALTER, which provides ease of programming
with the greatest possible flexibility.
HELITRONIC G 200 from WALTER: new innovative
tool grinding machine concept on a small footprint
further information: www.walter-machines.de
40 no. 1, March 2022

Top productivity for large workpieces
machining center
work with a pallet size of 800 x 800 mm with
axis travel of 1,400 x 1,200 x 1,350 mm and a
load capacity of up to 3,000 kg. Extremely durable,
powerful spindles ensure particularly
high machine availability.
Increased productivity thanks to
uninterrupted operation
The MA-8000H can be equipped with more
additional pneumatic and hydraulic connections
through the pallets making optimum
use of specific requirements for unmanned operation.
For example, this enables automated
loading and unloading processes during
machining time. The machine has also been
designed so that even a very large volume
of chips can be reliably removed – ensuring
maximum machine capacity utilisation. The
“sludge less tank” option developed in-house
also prevents accumulations of small chip
residues in the coolant tank, significantly
reducing the effort required for its cleaning.
The integrated Okuma OSP-P300MA control
system also makes it very easy to operate
and can be supplemented with various control
technology applications at the customer’s request.
Set-up and maintenance of the new machining
center has also been significantly simplified
by a particularly user-friendly machine
design.
The Okuma MA-8000H machining center
By introducing the new horizontal MA-8000H machining
center on the market Okuma is able to optimally meet corporate
requirements for automated manufacturing solutions for large
workpieces.
The particularly high powered model in the MA-H series gives customers
a number of advantages: the production capacity for large workpieces has
been significantly increased and productivity improved thanks to increased
automation options. In addition to that, energy consumption can automatically
and sustainably be drastically reduced by using special features.
The dimensions and performance capabilities of the new MA-8000H
have been massively increased compared to the previous model so that its
handling of very large and heavy workpieces is even better: the machine can
Reduced environmental impact
with maximum precision
It is becoming increasingly important to companies
to significantly reduce their CO 2
emissions,
especially in the field of semiconductor
production, renewable energies or when manu -
facturing e-vehicles. Okuma meets this requirement
perfectly with the new MA-8000H
thanks to various energy-saving features: the
proven thermo-friendly concept guarantees
highest dimensional stability and accuracy –
even in long-term operation. The integrated
“ECO suite plus” provides an innovative
energy saving system which allows the user
to monitor and adjust energy consumption
and CO 2
emissions in real-time. The machine
automatically reduces its power consumption
during idle times while maintaining stable
accuracies. Delivery of the MA-8000H will
start in Europe in July, with pre-orders being
accepted now.
further information: www.okuma.eu
no. 1, March 2022
41

components
Medical technology
More efficiency in the manufacture of
cardiovascular products
Since its foundation in 1970,
Aerotech has developed into a reliedupon
partner of the medical industry.
Their medical business unit has long
been one of the strongest in terms of
innovation and turnover of motion
con trol and positioning systems. The
steadily growing portfolio includes
laser welding and stent cutting solutions
as well as purpose-built motion
systems and components that can increase
throughput while maintaining
maximum precision. Over the years,
Aerotech has become one of the main
suppliers of motion control systems for
the manufacture of implantable interventional
cardiovascular devices.
“Aerotech’s commitment to quality and performance
has always been a perfect fit for
the needs and requirements of the medical
industry. So it was natural for us to focus
more on this industry,” says William Land,
business development manager for Aerotech,
Inc. and responsible for the medical device
market segment. Even more than other industries,
medical technology requires a
deeper technical understanding of the applications
and manufacturing requirements.
“Working closely with partners and customers
on an ongoing basis has given us the
industry insight we need to provide valuable,
future-proof automation solutions to
medical OEMs for nearly 50 years,” he says.
First and foremost, it is a matter of understanding
the needs and developments of the
market. Another important task is to keep
up to date and closely observe which medical
technology developments the industry is
focusing on.
“We must always be pushing our capability
developments to realise the desired
medical technologies of the future,”
William Land continues.
William Land,
business development manager
at Aerotech, Inc.:
“Working closely with partners
and customers on an ongoing
basis gives us exactly the industry
insights we need to provide
valuable and future-proof
automation solutions to medical
OEMs for nearly 50 years”
Integration and automation partner Aerotech was involved in the development of some of the first lathes for cutting intraocular
lenses and has been supplying specialist products to the interventional cardiovascular industry since the early 1970s. As a result,
Aerotech has world-renowned tube laser machining systems that are relied upon by the largest medical OEMs and device
manufacturers in the world. “We are able to manufacture fully integrated machines for custom applications,” asserts
William Land, business development manager at Aerotech, Inc.
42 no. 1, March 2022

components
Precise laser processing at maximum speed
In the field of interventional cardiovascular device manufacturing,
Aerotech is one of the main suppliers of motion control
systems and has been for many years. “We manufacture
custom-built linear and compact rotary servo systems
that are critical to the manufacture of stents and many other
trans-catheter devices and their delivery systems,” explains
William Land. “Our mature technology enables precise laser
processing of catheters and stents at speeds that make them
economical for the market.”
Fewer machines for the same number of stents
For example, the fully-integrated VascuLathe motion system
combines automated material handling functions with direct-drive
linear and rotary motion. “Because of the throughput
a truly integrated design offers, medical device manufacturers
need fewer machines to produce the same number
of stents compared to conventional production methods,”
William Land says of the benefits. However, due to its flexibility,
the VascuLathe can also be used, for example, to meet
an increased and varying production demand on the existing
production area.
Precise microlaser processing is particularly in demand
in medical technology; the AGV3D laser scanner is
optimally designed for this, but is also used
in additive processes
Innovations for the entire industry
“As experienced developers and automation partners, we can
keep pace with the very short innovation cycles in the industry,”
emphasises Simon Smith, European director at Aerotech.
“This future-oriented, constructive cooperation at eye level is
very much appreciated by our customers.” The stent manufacturing
solution is also merely a continuation of the successful
high-performance motion systems and components
for medical technology and life science applications.
Other examples from the medical technology solution
range include stent, guidewire, and catheter cutting, pacemaker
and catheter laser welding systems, intraocular lens
(IOL) and contact lens manufacturing, DNA and blood sequencing,
X-ray machines, MRI scanners and CAT scanners.
VascuLathe: innovative cutting system for
precise stent production at high throughput
Automated material handling
As a complete motion and material handling subsystem, Vascu -
Lathe includes an automated, pneumatically-activated ER collet
assembly and an optional combined bushing/tube feed mechanism.
This enables the sequential, fully automated produc -
tion of various products from tube material of any length.
Also a wet cutting configuration is available for applications
that require cooling fluid during the cutting process.
Advanced control architecture
As a platform, the VascuLathe is available with a powerful,
yet simple and intuitive Aerotech controller. Users can optimise
current, speed and position servo loops for maximum
performance without much programming. Additional functions
such as multi-block lookahead minimise geometry
errors even at the smallest radii by “anticipating” tracking
errors. With the “position synchronized output” (PSO) function,
laser pulses can be controlled synchronously in order
to maintain optimal laser power coupling at variable cutting
speeds.
Customer-focused integration
One of Aerotech’s focuses is to provide exactly as much integration
as the customer needs. “Many medical OEMs have
in-house automation and machine-build groups or preferred
integration partners,” specifies William Land. “Aerotech is
considered the first point of contact and subject matter experts
for precision motion control subsystem integration for
these teams.”
In other cases, medical OEMs were looking for a partner
to help them manufacture the entire manufacturing cell for
a specific process. “We are able to produce fully integrated
machines and manufacturing systems for individual application
areas,” assures William Land. “In every case, we ensure
that the systems we have in operation at our customers’ facilities,
whether individual components or complete machines,
operate at full capacity and deliver high-quality results.”
And Simon Smith emphasises in conclusion: “Manufacturers
of cardiovascular products gain a competitive advantage
in the highly competitive market of medical device
manufacturing with our high-precision motion systems
and components. We will be happy to advise interested
parties in detail. We would also be pleased to welcome you
on our new homepage.
further information: www.aerotech.com
no. 1, March 2022
43

components
We don’t have to be there to be there
In these times of local and national lockdowns
due to Covid-19, the manufacturing
sector has continued to support the economy
by continuing to work in safe and
managed environments. However, in these
times, the requirement for technical support
to maximise cutting tool performance
remains a priority. With travel restrictions
and lockdowns this could prove difficult to
deliver, but with its new LiveTechPro app
CERATIZIT is providing the platform for
its technical sales and applications engineers
to have their eyes and ears there with
you when you need them.
The innovative “LiveTechPro” solution from
CERATIZIT provides immediate and competent
visual support to deliver technical assistance in
case of machining issues or simply to help optimise
processes. It features a live, bidirectional
video and audio connection between the customer’s
machine operator/production engineer
and the technical support team from Ceratizit.
This ensures a reliable service that can be activated
within seconds to ensure production continues
to run smoothly. “Whilst our success has
been built on the direct technical support our
engineers give our customers on site and we
would always want to work this way as a first
choice, we are operating in extraordinary times
and facing new challenges on a daily basis and
ongoing support for our customers remains our
main priority,” says Tony Pennington, managing
director, Ceratizit UK & Ireland. “The LiveTech-
Pro app is the next best thing to a physical
visit, allowing our team to provide that support
remotely and ensuring that customers continue
to benefit from the performance advantages of
our latest tooling developments.”
The technology involved with LiveTechPro will
enable detailed discussions to take place as if a
Ceratizit engineer was on-site, specific issues or
elements of a component can be highlighted on
screen, downloaded if necessary, for detailed
discussion with responses and solutions being
provided there and then in terms of technical
advice. The LiveTechPro system allows for multiple
levels of operation via smartphone or tablet,
with conventional video being the starting point.
However, it is also compatible with virtual reality
technology to take support to the next level,
with virtual hands-on support. “It is the next best
thing to actually standing next to a machine, it
Ceratizit’s LiveTechPro allows operators and engineers to get live access
to cutting tool issues deep within the machine tool
With LiveTechPro Ceratizit’s technical support is always by your side
will be our eyes and ears during these times of lockdown and reduced
personal interaction as and when we cannot physically make a visit, as
the interface between customer and Ceratizit employee using LiveTech-
Pro is seamless and provides the reassurance that our technical sales and
applications engineers don’t have to be there, to be there for them.”
The LiveTechPro app is available for iPhone and Android operating
systems and can be downloaded directly from Ceratizit website or the
appropriate App Store.
further information: www.ceratizit.com
44 no. 1, March 2022

components
Live tool speed increaser realizes 9X tool cost savings
in less than a year
Kurt Machining (Minneapolis, Minnesota) specializes
in providing precision CNC machined parts, using
state-of-the-art technologies and up to 5-axis machining.
Since 1952, this 110,000 ft. 2 shop has provided its
customers in a variety of high-quality demand markets
with components and welded assemblies. These include
aerospace, defense, semiconductor, energy, automotive
and more. A very flexible shop, Kurt produces
parts ranging from micron-sized semiconductor components
to 2000 lb. workpieces for the defense sector.
On a recent project, where 5,000 pieces of 6,060 aluminum
were to be engraved on a Hwacheon horizontal turning
center, Kurt engineering manager, Shawn Eisenshank, had
concerns over the cycle times. He turned to his local tooling
distributor, Abrasive Specialists, Inc. (ASI) and their tooling
partner, Platinum Tooling, for suggestions. Leigh Kinnan of
ASI worked with the local Platinum Tooling representative,
Cody Papenfus, to test run a Heimatec speed increaser, with
the goal of increasing RPM on the machine and decrease
part cycle time, with a documentation of the potential savings.
After performing the calculations in consultation with
Preben Hansen, president of Platinum Tooling and exclusive
importer for Heimatec products in North America, it was
determined a significant savings could be realized.
As Shawn Eisenshank notes, “This is one of those classic
scenarios, where the theoretical has proven out in practice,
as we’ve seen exactly the results ASI and Platinum Tooling
proposed in their test calculations.”
Cody Papenfus of Hexis in Plymouth, Minnesota, who is
the area rep for Platinum Tooling adds, “We say we put our
expertise to work at the spindle of the machine and, in this
case, that’s exactly what happened. The speed increaser performed
as expected, the customer got the results promised
and it was a win-win, for all. We serve our customers for the
long haul and successes like this one are the big reason.”
Detailing the application, ASI demonstrated that a 1:3
speeder increased the spindle RPM enough that when coupled
with the nearly 3X increase in the feed rate on the machine,
would produce a significant improvement to the current
machining cycle. Calculating the reduction in machining
cost per part and factoring the cost of the speed increaser,
it was determined the use of the Heimatec product onboard
the Hwacheon turning center would result in a 9X cost saving
for the customer, in the first year’s production run on this engraved
aluminum component.
Kurt Machining performs both vertical and horizontal
milling and turning, complex assemblies and weldments, delivering
with rapid lead times. CAD compatibility is offered
for web-based communications and fully interactive manufacturing
engagement for its customers. The company performs
contract manufacturing in high quantity as well as
prototyping for new designs. Kurt also performs impact extrusion,
heat treating and cleanroom operations including
ultrasonic cleaning of stainless steel and aluminum components
and assemblies, with cleaning to Class 1000 with 100
protocol. The company is ISO 9001:2015 and AS9100D plus
NADCAP certified. Kurt Machining is quality certified by
the U.S. Government to MIL-Q-9858 and MIL-I-45208.
further information: www.platinumtooling.com
no. 1, March 2022
45

components
New CNC software simplifies usage of
latest five-axis machine tools
Available now, the latest version of Flexium software
from CNC specialist NUM includes an enhanced
RTCP (Rotation Tool Center Point) function with tool
vector programming that significantly simplifies the
usage of five-axis machine tools.
As one of the original developers of RTCP, NUM continually
enhances the function to meet the changing needs of machine
builders and end-users. The company’s implementation
of RTCP includes twenty-four predefined kinematic configurations
and its Flexium+ CNC systems can accommodate different
kinematics on the same machine, for example, when
different milling heads are needed.
NUM’s basic RTCP function, invoked by ISO code G151,
offers a number of user-specified variants. The function can
be activated with an inclined coordinate system or after a positioning
move. In either case, the CNC system automatically
calculates the mechanical offset to ensure that the tool center
point is always in touch with the defined workpiece surface
The RTCP function in
NUM’s Flexium CNC
software can now be
activated by the actual
positions of the rotary axes
The tool vector programming option of NUM’s RTCP
function enables the direction of the tool to be determined
by the vectors’ components along the X-, Y- and Z-axes,
rendering the part program independent of the machine
kinematics.
In some circumstances, aligning the workpiece to be
processed on the machine can be a complex procedure. In
these cases, to increase productivity, instead of moving the
workpiece, NUM’s Flexium+ CNC system can now compensate
for positioning deviations (including angles) by applying
appropriate correction values. The workpiece remains misaligned,
but the CNC system is aware of the deviations and
compensates for them automatically.
NUM’s Flexium software, version
4.1.00.00 or higher, now features
a special HMI (Human-Machine
Interface) to allow the corresponding
correction values to be
entered. The coordinate system resulting
from the shifts and rotations
is called a Balanced Coordinate
System (or BCS) and the compensation
function is known as 3DWPC
(3D workpiece compensation).
NUM’s Flexium CNC software now includes an enhanced RTCP function with
3D workpiece compensation that significantly simplifies the programming of
five-axis machine tools
Also the software now includes a
function to help machine users accelerate
the roughing operation’s
tunings and then achieve optimal
surface finishes. Invoked by ISO
code G732, the new function simplifies
parameter optimisation and
automatically computes pre-settings
for roughing and finishing with
adjustable smoothing levels.
while the rotary axes are moving. The RTCP function can
also be activated by the actual positions of the rotary axes.
Until now, programming 5-axis machines has often been
considered an onerous task. The rotary axes are usually programmed
directly with their angular position, which has
the advantage that the position of the machining head can
be imagined when viewing the part program. The disadvantage
is that the part program depends on the kinematics of
the machine, and cannot be transferred to another 5-axis
machine without modification.
To help machine operators achieve optimal results, NUM
has introduced a new algorithm that keeps the pivot point at
constant speed. Part programs generated by CAD/CAM systems
invariably comprise a multitude of small G01 segments –
in the case of rotary axes, these are often distributed inhomogeneously
– resulting in speed variations which affect surface
quality. The new algorithms maintain constant speed at
pivot points during the movement of rotary axes, smoothing
the discon tinuities, resulting in an improved surface.
further information: www.num.com
46 no. 1, March 2022

components
New lubricant for mask production
The manufacturer of ultrasonic welding equipment
for mask production, among other things, wanted more
process reliability in the machining of materials that are
difficult to machine: with tools from Paul Horn GmbH
and cooling lubricants from Zeller+Gmelin, the Karlsbad-based
specialist for ultrasonic components and
systems was able to find two suitable partners at once.
Ultrasonic welding from
Weber Ultrasonics is used for
the production of medical masks
The ultrasonic
sys tems are used,
for example, in
the production of
a wide variety of
medical technology
applications,-
for example medical
masks or components
such as
membranes,
adapters, connectors
and even sur -
gical instruments.
In particular, the
demand for ultrasonic
welding technology
for the series
production of
medical masks
made of non-woven
fabric has increased
dramatically
due to the
pandemic. The ver -
tical range of
manufacture at
Weber Ultrasonics
is enormous: almost all components and assemblies of the
ultrasonic systems are manufactured in-house. For a special
titanium component, the so-called converter, the machining
process used is grooving, or more precisely axial grooving. In
order to be able to guarantee process reliability and long tool
life even with increasing quantities, new tool solutions were
sought. Previously, chatter marks on the surface of the deep
grooves were a recurring problem.
Zubora ensures more process reliability
With a new axial grooving system from the Tübingen tool
specialist Horn, a process-safe solution was found: the new
S15A grooving insert had produced a stable machining process
right away. At the same time, a new cooling lubricant
is used in the form of Zubora TTS, which was developed
in a joint project between Horn, Zeller+Gmelin and a major
machine manufacturer. “All the experience of the lubricant
manufacturer, machine builder and tool specialist has
gone into the development of the new lubricant,” says Jürgen
Schmid, product and project manager sales at Horn, seeing
By using the newly developed cooling lubricant Zubora TTS
in combination with the axial grooving system from Paul Horn,
swirl chips are now optimally broken during the machining
of pure titanium TiAI6V4 and ensure a safe process
an enormous advantage. “The idea of the project was to develop
a new and more efficient coolant for the machining of
superalloys. Zeller+Gmelin has achieved this with the development
of the new coolant.” And business unit manager
Thorsten Wechmann from Zeller+Gmelin adds: “After
successful tests on various superalloys, the first field test at
Weber Ultrasonics was now on the agenda. By using Zubora
TTS in combination with a new tool coating, the tool life
could be significantly increased. The completely new formulation
leads not only to an increase in tool life but also to an
improvement in the surface quality of the component. Furthermore,
it was possible to increase the cutting parameters
and thus sustainably increase profitability.”
Chip breaking under control
Weber Ultrasonics says that by optimally matching the tool
and the cooling lubricant, it has been possible to significantly
improve chip control. As a result, 50 of the titanium components
can now be produced off the shelf in an unmanned
shift, so to speak, and the problem of uncontrolled long chips
is now a thing of the past. Tool wear has also improved measurably
and visibly thanks to the new Zubora coolant.
The new cooling lubricant Zubora TTS is a fully synthetic
solution. According to manufacturer Zeller+Gmelin, the
focus of the novel concept was on lubrication, chip breakage
support and surface quality improvement. “We have developed
the new coolant for the productive machining of titanium
and other super alloys. However, the product can be
used multifunctionally and also brings advantages when
machining a variety of other materials,” explains Thorsten
Wechmann.
further information: www.zeller-gmelin.de
no. 1, March 2022
47

components
A sensible addition to
mechanical clamping elements
ENEMAC, the clamping specialist offers now the
new series ESG clamping nut, which perfectly complements
the established types ESB and ESD.
The clamping force is strengthened by a special crowngear
transmission with a rectangular deflection of the
rotation and lateral manual operation. Thanks to the
newly designed power transmission elements, ESG
achieves significantly lower height and overall compact
dimensions compared to the ESB and ESD types, which
allows its use in extremely cramped conditions.
By turning a small nut, which is attached to the side of
the housing, the internal gear is driven with a minimum
force effort and the counterpart is tightened.
The principle is simple, the effect very large, because
this concept allows a clamping force of 12 t to be manually
applied by each worker. Thread sizes from M16 to
M30 are available. The power clamping nut is screwed
onto the existing bolt, then tightened through the lateral
hexagonal bolt to the specified torque using a commercially
available torque wrench. The clamping nut secures
your workpiece or tool safely and quickly. The series
ESG has been designed for workpieces and tools with a
varying component size since the screw depth is not restricted
due to the continuous thread.
For harsh environment applications there are special
variants such as high temperature versions up to 673 K.
Optionally available is a version with additional disc
spring package for compensation of the clamping upstroke,
which is recommended when clamping heavy
compactor dies for the higher operation safety.
The ENEMAC power clamping nuts can be used at
any time, whether by the original equipment manufacturer
or as a retrofitting element.
further information: www.enemac.de
Measuring high-precision master workpieces
Precision requirements for workpieces are becoming
more demanding and are often in the micrometer
range. This means that requirements for master workpieces
for gaging benches and machines as used in the
automotive industry are also increasing. The Video-
Check® V HA, like all Werth machines, is traceable and
can be used to calibrate the calibration masters at the
factory.
If the quality management system requires a DAkkS certificate,
the machine can be calibrated by Werth’s own DAkkS
lab in accordance with DIN EN ISO/IEC 17025. Werth
is the first and only manufacturer to provide DAkkS calibration
certificates for optical, and tactile, and computed tomography
coordinate measuring machines. DAkkS (Deutsche
Akkreditierungsstelle) is the national accreditation body of the
Federal Republic of Germany. It is legally mandated to carry
out accreditations of conformity assessment bodies.
With its solid granite construction, special air-bearing
technology, and thermally stable scale system, the Video-
Check® V HA achieves measurement uncertainty in the range
of tenths of microns. The high-precision machine has an
integrated vertical rotary
axis to prevent heavy
workpieces such as shafts
and tools from sagging
under their own weight.
In addition to external
dimensions, the flexible
3D machine can also measure
a number of other
features, such as teeth,
transverse holes, etc. The
VideoCheck® V HA is also
available for workpieces
up to 1000 mm in length
and 320 mm in dia meter.
The combination of image
processing and the SP80
tactile sensor allow for the
very highest measurement
precision.
VideoCheck® V HA – higher
precision with a larger
measurement range
further information: www.werth.de
48 no. 1, March 2022

components
Clear conditions for tool grinding
The KFA 1500 Compact Filter System is a high-performance, low-maintenance ultra-fine
filter system for grinding high-speed steels (HSS) and carbide materials, which promises
optimum quality with high cleanliness of NAS 7/8 or 3-5 µm even for very large batches
The larger the tool grinding batches and the more
grinding machines are involved in the filtration process,
the more necessary are high-performance largescale
and special filter systems for cleaning contaminated
grinding oils. With the KFA 1500 Compact Filter
System, the machine manufacturer Vomat from
Treuen (Germany) provides tool manufacturers and
regrinders with a high-performance, low-maintenance
ultra-fine filtration system for grinding high-speed
steels (HSS) and carbide materials, which promises optimum
quality with high purity of NAS 7/8 or 3-5 µm
even for very large batches.
Demanding grinding applications require a high-performance
filter system that positively supports and influences
the process flow. Ultra-fine filtration allows grinding oils to
remain in the system significantly longer. Cleanly filtered,
they help to increase the dimensional accuracy and surface
quality of the products. Additionally, the right filter system
also reduces energy consumption and disposal costs.
Vomat’s product portfolio includes solutions for stand-alone
systems, modular systems, central systems and individual
customized specialty systems with central and decentralized
functions. One example is the KFA 1500, a special ultrafine
filtration system that promises tool manufacturers and
regrin ders optimum economic quality even for large batches
of different materials. The KFA 1500 (260” x 100” x 103” h) has
a tank volume of 10,000 liters and a filter capacity of 1,500
liters/minute. The medium is filtered by high-efficiency
precoat filters in full flow at a filter fineness of 3-5 μm. Filtration
takes place on demand and in an energy-efficient
manner via a frequency-controlled system pump. The special
drying unit is optimally designed for large batch sizes.
The cooling performance in the cold water circuit of the
KFA 1500 is 200 kW in continuous operation. The temperature
accuracy in the tolerance range of up to +/- 0.2 ° C contributes
to the optimum quality of the product.
Due to the precoat principle, there is no contamination of
the swarf by filter aids. The residual moisture of the swarf is
between 5 and 10 % and the recyclable material is processed
directly into a suitable transport container for recycling companies.
The control technology can also be monitored and
operated remotely. Also VOMAT offers a compression cooler
with external condenser and high control accuracy, as well as
a material-dependent pre-separation system.
GrindTec 2022, hall 3, booth 3027
further information: www.vomat.de
no. 1, March 2022
49

fairs in alphabetical order
AMB Stuttgart, Germany
(September 13-17, 2022)
CCMT Shanghai, China
(April 11-15, 2022)
EMO Hanover, Germany
(September 18-23, 2023)
EPHJ Geneva, Switzerland
(June 14-17, 2022)
FABTECH Toronto, Canada
(June 14-16, 2022)
FEIMEC São Paulo, Brazil
(May 3-7, 2022)
FILTECH Cologne, Germany
(March 8-10, 2022)
GrindingHub Stuttgart, Germany
(May 17-20, 2022)
GrindTec Augsburg, Germany
(March 15-18, 2022)
Hannover fair Hanover, Germany
(May 30 to June 2, 2022)
IMT Brno, Czech Republic
(October 4-7, 2022)
IMTS Chicago, USA
(September 12-17, 2022)
intertool Wels, Austria
(May 10-13, 2022)
JIMTOF Tokyo, Japan
(November 8-13, 2022)
METALEX Bangkok, Thailand
(November 16-19, 2022)
METAV Düsseldorf, Germany
(June 21-24, 2022)
SIMTOS Seoul, South Korea
(May 23-27, 2022)
sps Nuremberg, Germany
sps on air digital (November 8-10, 2022)
Stone+tec Nuremberg, Germany
(June 22-25, 2022)
Surface Stuttgart, Germany
Technology (June 21-23, 2022)
TIMTOS x TMTS Taipei, Taiwan
(February 21-26, 2022)
current status
2022
2022
2023
2022
2022
2022
2022
2022
2022
2022
2022
2022
2022
2022
2022
2022
real &
digital exibition
2022
2022
2022
2022
2022 real &
digital exibition
TIMTOS x TMTS Taipei, Taiwan
(February 21-26, 2022)
2022 real &
digital exibition
trade fair dates as by beginning of February 2022; we are not responsible for reliability of these dates
50 no. 1, March 2022

impressum
ISSN 2628-5444
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copyright © 2022 Dr. Harnisch Publications
editorial
Aerotech, Inc. ...................... 42
BMR elektrischer und elektronischer
Gerätebau GmbH ..................34
Boehlerit GmbH & Co. KG ............17
CemeCon AG .......................12
CERATIZIT Deutschland GmbH .. 18, 44
CHIRON Group .....................25
EMAG Group ...................... 24
ENEMAC Gesellschaft für Energie- und
Maschinentechnik mbh ............ 48
Gleason Corporation .................22
GrindingHub .......................25
GrindTec 2022 ......................21
Hartmetall-Werkzeugfabrik
Paul Horn GmbH ..................13
Haas Schleifmaschinen ...............38
IFR International Federation
of Robotics ....................... 20
KAPP GmbH & Co. KG ..............30
KREBS & RIEDEL SCHLEIFSCHEIBEN
FABRIK GMBH & CO. KG. .........19
advertising index
company finder
Lach Diamant
Jakob Lach GmbH & Co. KG ..........6
Leitz GmbH & Co KG ................10
Liebherr-Verzahntechnik GmbH ......35
MAPAL Fabrik für
Präzisionswerkzeuge Dr. Kress KG ...11
MAG IAS GmbH ....................26
NUM AG .......................... 46
OKUMA Deutschland Gmbh .........41
PLATIT AG .........................14
Platinum Tooling ....................45
TORNOS SA ........................36
UCIMU-SISTEMI
PER PRODURRE. .............. 22, 24
UNITED GRINDING Group .........23
Vomat GmbH .......................49
Walter Maschinbau GmbH .......... 40
Werth Messtechnik GmbH. . . . . . . . . . . 48
Zeller+Gmelin GmbH & Co. KG .......47
Aerotech GmbH ........................................................page 11
Boehlerit GmbH & Co. KG ...............................................page 3
CERATIZIT Deutschland GmbH .........................................page 5
Günther Effgen GmbH ..................................................page 13
JIMMORE International Corp. ...........................................page 19
KAPP GmbH & Co. KG .................................................page 21
Lach Diamant Jakob Lach GmbH & Co. KG .............................front cover
PLATIT AG ...................................................inside front cover
Reishauer AG ....................................................... back cover
VDW – GrindingHub ...................................................page 17
no. 1, March 2022
51

Eyed Industry 4.0
ARGUS EYES ON THE GRINDING PROCESS
Reishauer‘s ARGUS process and component monitoring provides unprecedented insight into grinding
and dressing processes and the condition of critical machine components. Process Monitoring
and optimize with data analysis, identify necessary maintenance work in advance, plan
efficiently and reduce downtime to a minimum - ARGUS makes it possible:
• Grinding and dressing process monitoring
• Collision monitoring
• Monitoring of machine components
• Web-based process view
• Data analysis
• Process optimization
• Potential zero-defect production
Reishauer AG, Switzerland | reishauer.com