hp tooling 2022 #2

ISSN 2628-5444
high precision tooling
Machine Tools, PCD, PVD, CVD, CBN, Hard Metal 2022 – 2
■ Carbide grade for machining superalloys ■ Sharpening skiving cutters ■
■ Spotlight on energy and resource consumption ■ Measuring and positioning cycles synchronise exactly ■

VISIT US AT GRINDINGHUB
IN STUTTGART, GERMANY
17.–20.5.2022
GrindingHub
17.–20.5.22
hall 9,
booth A50
At GrindingHub in Stuttgart, two STUDER
innovations will also be unveiled at the
UNITED GRINDING Group joint booth. Visit us
on the first day of the trade fair, May 17, 2022,
at 10 am.
studer.com/grindinghub
The Art of Grinding.
A member of the UNITED GRINDING Group

editorial
“Play it again…
Eric Schäfer
editor-in-chief
…Sam”. This legendary phrase
from the 1942 film classic
“Casablanca” is an ideal motto
for the current hp tooling issue.
Grinding, sharpening, and
gear cutting are the machining
processes that also give this
issue the necessary polish.
After all, GrindingHub, the
next international trade fair
for grinding technology, is
just around the corner.
There the focus will be on sustainability in connection with
tools and machines. In times when the efficient consumption
of energy and resources is crucial, optimized manufacturing
process design and optimum use of grinding processes play
a major role. The International Energy Agency (IEA), for
example, sees energy efficiency as by far the strongest lever
for CO 2 reduction. To improve the relationship between
productivity and energy consumption, it helps to know how
much energy is required and consumed and at which point
in the process. In a machine tool, for example, the auxiliary
units for cooling lubricant supply, cooling and hydraulics are
the largest consumers, as scientific studies by RWTH Aachen
University have recently discovered. Together with the main
spindle, they account for more than two-thirds of a machine
tool’s energy consumption.
Resource-saving production is particularly relevant to
grinding operations. This is because grinding is considered
an energy-intensive manufacturing process within the
process chain, since a comparatively small workpiece volume
is machined at high cost. You can find out more about this in
our preliminary report on GrindingHub, which invites you
to think beyond the grinding process.
Thinking beyond boundaries, expanding your horizons –
that’s what we invite you to do with every issue of hp tooling.
Our user reports take you on a journey around the world.
This time, it’s off to Japan, India and Southeast Asia, to the
USA and to Birmingham in England.
Eric Schäfer
editor-in-chief
Top-level quality
10. - 13.
May 2022
Hall 21,
Booth 0635
■ The new longitudinal and circular weld
seam milling tools from Boehlerit guarantee
maximum performance and precision
■ The new VARIOtec 00P turbine blade milling
system offers specially matched carrier
bodies and cutting materials
■ The existing Quattrotec range has been
expanded to include the diameters
18 and 25 mm
■ Carbide rods and special solutions:
New are the utrafine grain grade HB05UF
and the grade XS10 optimized for
diamond coating
■ New steel turning generation -
High performance, maximum economic
efficiency
www.boehlerit.com

table of contents
cover story
Miles ahead of the competition with the electric race car
Additively manufactured solutions inspire the Formula Student team from Stuttgart 6
materials & tools
Introducing carbide grade that excels in machining superalloys 11
Titanium machining takes off 12
LACH DIAMANT looks back on 100 years – 12 th part
Efficiency concept for re-sharpening all dia tools (PCD) for the wood,
furniture and composite industry 14
Long-lasting in non-ferrous metals 16
Gripping and clamping from a single source 16
processes
From the desired gear to the perfect skiving tool 24
Sharpening skiving cutters for new EV transmissions 26
Spotlight on energy and resource consumption at GrindingHub 28
The tiger leap with HiPIMS in Southeast Asia 31
machining center
TSCHUDIN puts the focus on versatility 32
Automated laser processing of diamond tools 34
“Everything for the perfect gear” 37
Cutting-edge technologies for high-precision surface machining 37
Unmanned cylindrical grinding processes for small series 38
CUT X series of wire-cutting EDM machine 42
components
Measuring and positioning cycles synchronise exactly 44
Strategic partnership with Japanese tool grinding machine manufacturer 46
Sealing technology increases plant and process reliability 49
An eye for details 50
news & facts 17
fairs 5, 23
impressum & company finder 51
4 no. 2, May 2022

fairs in alphabetical order
AMB Stuttgart, Germany
(September 13-17, 2022)
bauma Shanghai, China
(November 22-25, 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)
GrindingHub Stuttgart, Germany
(May 17-20, 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)
MACH-TECH and Budapest, Hungary
INDUSTRY DAYS (May 10-13, 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)
current status
2022
2022
2023
2022
2022
2022
2022
2022
2022
2022
2022
2022
2022
2022
2022 real &
digital exibition
2022
2022
2022
2022
trade fair dates as by middle of April 2022; we are not responsible for reliability of these dates
no. 2, May 2022
5

cover story
Miles ahead of the competition with the electric race car
Additively manufactured solutions inspire the Formula Student team from Stuttgart
A race atmosphere without petrol in the air and
full speed ahead with electric power? For the Formula
Student GreenTeam at the University of Stuttgart, this
is now a reality with its fully electric race car with help
from CERATIZIT and additive manufacturing. The
additively manufactured wheel carrier is part of the
reason behind the student racing team coming top in
the rankings: ensuring that the challenging finishing
process was a success, CERATIZIT’s Project Engineering
Team also developed a machining solution to give
the project a significant boost.
What first comes to your mind when thinking about being
a student? Overcrowded lecture theaters, low-stress lectures
and leisure time in abundance? And then take out a year from
studying? What sounds like taking it easy and delaying graduating
takes on a far different meaning for the GreenTeam
at the university of Stuttgart: a total of 70 students dedicated
themselves exclusively for an entire year to creating a fully
electric car – from the development and construction through
to participation in the Formula Student season. Their success
has proven that the time and personal investment was
worth it: since 2009, the team has been among the top 10 in
Maximilian Ziegler (left) was responsible for the overall
management of the car mechanics and the development of the
new wheel carriers; together with CERATIZIT project manager
Tim Haudeck from the Global Project Engineering Team,
he is delighted with the excellent collaboration.
6 no. 2, May 2022

cover story
Fresh out of the 3D printer, the new wheel carriers for the
fully electric racing car of the University of Stuttgart’s
GreenTeam still required some rework.
The solution was an additively manufactured special tool
from CERATIZIT which could be used to meet even
narrow tolerances, and in a single setup
the world and has already broken the world record for accelerating
from 0 to 100 km/h twice. Hypercars like the Porsche
918 Spyder? The electric car racers from Stuttgart know them
well from the rear-view mirror!
Fully electric racing onto the winner’s podium
Strictly speaking, since 2016 the team has been working
on two cars year after year: a conventional model with a driver
and a driverless version, which, thanks to sensors and
artificial intelligence, competes in races without direct human
intervention. For the 2021 season, the team intended
once again to beat the competition. “We are one of the best
teams, which is why winning is everything to us,” explains
Maximilian Ziegler, who is responsible for the overall management
of car mechanics and the development of the new
wheel carriers. The new additively manufactured wheel carriers
play here a key role according to Ziegler: “Our E0711-
11 EVO model has enormous potential thanks to this, as the
relocation of the electric motors in the wheels significantly
improves the aerodynamics.”
Analysis is about experimenting
After intensive research, Max Ziegler finally contacted
CERATIZIT where the Global Project Engineering Team
deals with complex machining solutions for automotive
customers with exacting requirements on a daily basis.
CERATIZIT project manager Tim Haudeck accepted the
challenge. “We are constantly confronted with the limits of
what is possible and are always looking for ways to overcome
these limits. We were able to put our knowledge of e-mobility
to the test with the GreenTeam project,” says Haudeck.
Together with the GreenTeam and Renishaw, Tim Haudeck
and his team analysed the components, the 3D printing
Tricky and complex:
production of the wheel carriers
The production of the new wheel carriers was as complex as
the parts are advanced. “We therefore relied on the knowledge
and experience from the industry for their production,”
admits Ziegler. “And so, together with the experts for additive
manufacturing from Renishaw, we first set to work on optimising
the components for 3D printing.”
However, the next challenge wasn’t far away, as Ziegler explains:
“After the 3D printing we needed a solution for machining
several surfaces.” The search wasn’t easy, and many
companies shied away from this request. The combination of
a complex component with diameters above 120 mm, minimal
wall thicknesses of below 1 mm and narrow IT6 tolerances
on the internal and external surfaces to be machined
was too tricky.
The combination of a complex component with diameters
above 120 mm, low wall thicknesses of below 1 mm and
narrow IT6 tolerances on the internal and external surfaces
to be machined was too tricky for most companies
no. 2, May 2022
7

cover story
The name is still a bit of a mouthful, but the
racing season was all the more successful for the
E0711-11 EVO model of the
University of Stuttgart's GreenTeam
requirements and the postprocessing to further optimise the
wheel carriers. “It became clear that we would barely meet
the required tolerances with a standard solution.”
The solution: U-axis and 3D printing
Even with a special solution the requirements were still high.
“For machining on a 5-axis machine with HSK63 interface,
we had to reduce any imbalance and minimise the weight.
Otherwise the required tolerances would not be met. The way
to this was clearly an additively manufactured solution,” adds
Haudeck. To meet the IT6 tolerances, all important diameters
and fits should be machined in one setup. To do so, the Engineering
Team constructed an additively manufactured attachment
with two adapters for indexable inserts and a vibration
damper, which was mounted on a U-axis. The lightweight,
FEM-optimised design optimally absorbs the forces acting
during machining and thanks to additive manufacturing,
cooling directly on the cutting edge is achieved.
First class thanks to additively manufactured
wheel carriers
Supporting the development process and tracking the machining
of our component was also a highlight for Maximilian
Ziegler: “Working with CERATIZIT and Renishaw was fantastic.
We work at eye level and share the same passion,” says
Ziegler enthusiastically after completion of the first component.
Has the considerable effort involved in the additively
manufactured wheel carriers paid off for the team? “Definitely.
We were able to secure first place twice and second place
once in the overall rankings in four races in the 2021 season.
The car is everything we could have hoped for. For me personally
though, working with CERATIZIT was also excellent;
everything went perfectly,” enthuses Maximilian Ziegler
about the start of the season.
Innovative solutions for automotive customers
For Tim Haudeck, the GreenTeam project is a prime example
of what can be achieved when you combine modern production
processes with the know-how of CERATIZIT employees.
“We would never have been able to produce components
such as the GreenTeam’s wheel carriers a few years ago.
It is only through additive manufacturing and the required
expertise that such parts can be realised. With our experience
in the automotive and e-mobility industry as well as our
Global Project Engineering Team, we are well equipped for
the requirements of the automotive industry.”
further information: www.ceratizit.de
8 no. 2, May 2022

materials & tools
Solid ball-nose end mill for high-hardness
material processing
Achieves long life, stable processing
with new shape and coating
Kyocera has announced the launch of its “2KMB”
solid ball-nose end mill for high-hardness material
processing and micromachining. Used in the fine machining
of precision parts and metallic molds, this new
solid round tool product is now available globally by
Kyocera.
2KMB is the second product launch in Kyocera’s “K-series”
solid tool line, which combines new coating technology with
a unique shape for the effective micromachining of various
high-hardness materials such as alloy tool steel, stainless
steel, and high-speed steel. Kyocera’s new wear-resistant coating,
“MEGACOAT R HARD EX”, features a unique two-layer
structure to ensure stable processing with high toughness and
exceptional chipping resistance. The wear resistance and chipping
resistance both contribute to higher quality and longer tool
life. In addition, the newly developed, unique S-shaped cutting
edge with outstanding sharpness achieves a high-quality
surface finish and maintains wear resistance. KYOCERA
strives to improve customers’ productivity with products that
optimize performance, economy, and functionality.
Features of 2KMB solid ball-nose end mill for micromachining
1. Proprietary “MEGACOAT® 1 HARD EX” coating technology extends tool life
• achieves stable machining with high toughness and outstanding chipping resistance
• long tool-life processing is possible due to superior oxidation resistance and wear resistance
• supports quenched hardened steel processing from tempered steel up to 70 HRC
2. Unique cutting-edge shape achieves superior sharpness and wear resistance
• s-shaped cutting edge achieves high-quality surface finish and high wear resistance
• wide core thickness increases tool rigidity, which prevents collapse and ensures stable processing
• point cutting (strong back taper) reduces collapse and prevents chattering
• unique cutting-edge shape gradually changes rake angle and clearance angle,
compatible with high blade edge strength and low resistance.
1
“MEGACOAT®” is a registered trademark of KYOCERA corporation
About End Mills
End mills have multiple cutting edges on the outer periphery
and bottom. They are used in various industries, such as
automotive, aerospace, and industrial machinery, to process
grooves and shoulders on metal surfaces by rotating and sliding
across the workpiece. To increase productivity, machinists
require end mills that can handle a wide range of applica-
tions and materials. These high-performance tools must also
deliver high-precision machining and long tool life. In addition,
ball-nose style end mills are used to cut more complicated,
three-dimensional, curved surfaces such as radii and
spherical machining applications.
further information: www.kyocera.co.uk
no. 2, May 2022
9

materials & tools
Gear cutting to the power of three
Gear broaching, gear milling and gear skiving are the three core areas targeted by the joint campaign of
Paul Horn GmbH and DMG MORI
Gear broaching, gear milling and gear skiving
– otherwise known as the technology cycles:
gearBROACHING, gearMILL, gearSKIVING.
Paul Horn GmbH and DMG MORI have launched a campaign
covering these three core areas in gear cutting to demonstrate
the high performance of the solutions that have been jointly
developed through a combination of machine, cycle and tool.
A major advantage is that many existing machines can be
adapted to the individual processes.
Gear milling with standard tools up to module 3 achieves a
gear quality of ≥ 5. Gear quality of ≥ 9 can be achieved when
gear broaching internal and external gears up to module 4.
To provide practical proof of these results, there will be
numerous events and trade fairs in 2022 that will focus on
the joint gear cutting processes developed as part of DMQP
(DMG MORI Qualified Products). The first event will be the
DMG MORI Open House in Pfronten May 9 th to 21 st .
The exclusive DMG MORI technology cycles assist shop
floor programming for increasing productivity and safety
as well as for expanding machine capability. The advantages
are clear: up to 60 % faster programming, error minimisation
through conversational programming, new technologies
(gear cutting) and the technology know-how stored in the
application software.
As far as the tool is concerned, Horn’s standard or customerspecific
special tools may be used, depending on the process
and application. When skiving internal and external gears,
sizes up to module 8 are possible in gear quality up to ≥ 7.
further information: www.phorn.de
10 no. 2, May 2022

materials & tools
Introducing carbide grade that
excels in machining superalloys
Rotary tools made from new rod blanks
show improvement in tool life on
INCONEL ® workpieces
Hyperion Materials & Technologies, a
leading global materials science company
that develops hard and super-hard materials
for a variety of industries and applications,
announced today the launch of its
grade AM110 TM tungsten carbide rod blanks
that excel in machining superalloys such as
INCONEL.
Hyperion’s materials experts specially engineered
grade AM110 to optimize the hardness, toughness
and galling resistance required for machining superalloys
in today’s demanding industrial applications.
Some of the targeted markets include aerospace,
medical and energy, where quality and productivity
are critical to manufacturing precision
components.
“We are continuously working with our toolmaker
customers to develop improved grades and
products that help them solve their biggest challenges,”
said Ron Voigt, chief executive officer of
Hyperion. “Machining superalloys brings a different
set of challenges due to intense heat and high
pressure on the tooling. Our AM110 grade of carbide
rods can overcome these challenges, producing
tooling that delivers more predictable results
with cutting edges that break less often.”
Testing at Hyperion demonstrated that end milling
tools made with grade AM110 rod blanks performed
35 % better on INCONEL workpieces compared
to conventional tungsten carbide grades.
“One of Hyperion R&D’s strengths is the ability
to effectively combine our knowledge of customer
applications, expertise in machining mechanics
and deep exper tise in materials science to develop
cutting-edge carbide grades that deliver both
productivity and durability,” said Biju Varghese,
Hyperion’s vice president of Engineered Solutions
and Global R&D. “Our research and development
team achieved the ideal composition with grade
AM110 and delivered a product that provides a
superior balance between wear, galling and toughness
for superalloy machining.”
Hyperion offers grade AM110 carbide rods in a
variety of dimensions and finishes and as sintered
or ground to ISO h5 or h6 tolerances.
Innovation Award at
GrindTec for AM110 TM
Hyperion Materials &
Technologies collected
an Innovation Award at
GrindTec trade show in
Augsburg, Germany, for
its AM110 grade of tungsten
carbide rod blanks
used to make tools for machining superalloys.
“Winning this award is a testament to the hard work of everyone
on the Hyperion team,” said JP Camardo, general manager of
Carbide Rods at Hyperion. “From the teams in the field to the
research and development group, it was a true team effort to
develop the ideal composition with grade AM110, delivering
a product that provides a superior balance between wear,
galling and toughness for superalloy machining.”
further information: www.hyperionmt.com
Precise and
productive
CBN profile grinding discs
Liebherr-Verzahntechnik GmbH
One-, two- or three-ribbed CBN profile grinding
discs for internal gears
– High-quality internal gears for low-noise use in gearboxes
– Increased load capacity due to the high residual compressive stresses with
CBN grinding
– Individual grain sizes for different applications
– Shorter grinding times
– Roughing and finishing in a single process
– Longer tool life
– Time-consuming dressing not necessary with CBN tools
Liebherr-Verzahntechnik GmbH, tools.info@liebherr.com, www.liebherr.com
Grinding Hub: May 17-20
Hall 7, Booth C02

materials & tools
Titanium machining takes off
There are numerous applications waiting
for new titanium machining tools from
MAPAL. In medical technology, this workpiece
material is used for implants because
of its strength and compatibility with
human tissue. Automotive manufacturers
use it to create powerful sports cars. The
blades of large gas turbines, made of titanium,
absorb enormous forces. The aircraft
in dustry is producing more and more highly
stressed parts made of titanium. MAPAL
is making drilling and milling of the ductile,
high-strength workpiece material more
productive, thereby reducing costs.
New drills and milling cutters made of solid carbide
and milling cutters with indexable inserts
extend MAPAL’s standard portfolio for machining
titanium. All new developments feature high
cutting values and well thought-out heat dissipation.
In designing the tools, MAPAL followed the
requirements for titanium machining set by the
target markets. The range of available diameters
Innovative tools for milling and solid drilling of titanium
is correspondingly broad, starting with small sizes from 3 mm, as often
required in medical technology, through the medium sizes for sports car
components to the large tools for aircraft construction and energy technology.
In tests, MAPAL has recorded 25 to 35 % longer tool life for its
tools compared to competitors.
MEGA-Speed-Drill-Titan: cost-efficient and productive
The focus in the development of the MEGA-Speed-Drill-Titan was on cost
efficiency with maximum possible productivity. “Our goal was to develop
a solid carbide drill that can run at a very high feed rate in titanium materials,
resulting in very low cycle costs,” explains Jens Ilg. In contrast to
the assembly areas in aircraft construction, where no cooling lubricant or
only a small amount of MQL can be used given the already finished assemblies,
cooling lubricant can be used in parts production on machining
centers to machine titanium efficiently.
The new OptiMill-Titan-HPC solid carbide
milling cutter performs both roughing and
final cuts in titanium very reliably
MAPAL has equipped the drill with four guiding chamfers for optimum
roundness. Convex cutting edges and an efficient coating allow for
increases in tool life of up to 30 %. To get the maximum coolant flow to
the main cutter, the coolant channel is not open in the direction of the
chip flute, but the coolant is guided along the outside surface to the rear.
In this way, the guiding chamfers experience maximum cooling, dissipating
the heat generated effectively. MAPAL uses a new design for the chip
flute to produce the smallest possible chips and to discharge them through
the flute. Typical parts that can be created with the drill, which achieves
a cutting speed of up to 40 m/min, are structural parts in the aerospace
industry, for example brackets for the wing box or the landing gear with
its numerous bores.
12 no. 2, May 2022

materials & tools
OptiMill-Titan-HPC:
versatile roughing and finishing
The OptiMill-Titan-HPC roughing-finishing milling cutter is
a versatile tool. It is also ideal for smaller manufacturers who
prefer not to have a single milling cutter for every kind of
machining. The solid carbide tool can perform roughing
operations and can also be used for a finish cut. The special
cutting edge preparation produces clean surfaces and allows
finishing up to a working depth of 2xD. In conjunction with
the MAPAL Mill Chuck, optimum coolant supply via the
shank is possible. The core of this milling cutter with four
cutting edges rises from the cutting edge to the shank, giving
it greater stability. The spacing of the cutting edges and
the pitch of the spirals are uneven to achieve smooth running.
The coating, which contains silicon, and the polished
chip flutes are highly heat-resistant, counteract the tendency
to adhesion and therefore ensure optimum chip evacuation.
The OptiMill-Titan-HPC milling cutters are available in the
diameter range from 4 to 25 mm. Special dimensions are
available.
The OptiMill-Titan-HPC is the number one tool for manufacturing
titanium brake calipers for sports cars. MAPAL is
also successfully using the tool to manufacture a wide range
of parts for pilot customers. Rotor heads, door frames, flaps
and structural parts for vertical tail planes (VTPs) are just a
few examples.
Cost efficiency with the highest possible productivity –
the new MEGA-Speed-Drill-Titan from MAPAL
NeoMill-Titan:
indexable insert milling cutters with a bite
The NeoMill-Titan family of tools with indexable inserts for
titanium machining consists of shell end face milling cutters
in slip-on and shank versions as well as shoulder milling
cutters in the standard portfolio. MAPAL has developed
the topography of the indexable insert from scratch for optimum
chip formation and evacuation. An equally new cutting
material concept minimises wear and prevents the titanium
from sticking. The available corner radii of 0.8 mm to
4 mm are tailored to structural parts in the aerospace industry.
To save weight, several pockets are milled here, and their
final contour should already be achieved as well as possible by
pre-roughing. In the manufacturing of tail fin structures,
about 90 % of the material is removed.
MAPAL offers the indexable inserts with two different substrates.
One grade is designed for universal applications and
is aimed at customers whose focus is more on product price
and less on cost per part. The second grade is more temperature-resistant,
enabling higher cutting speeds and the machining
of more highly annealed titanium material. Cutting
speeds of up to 70 m/min can be achieved. “With this approach,
we specifically address the requirements of the market,” says
Tyczyński. “We take into account the individual needs of our
customers and offer an optimally fitting solution.” The tool
body has also been newly developed for the high-tech inserts.
With flowing shapes, the chip flutes transport the chips out of
the shear zone. The coolant is fed axially directly through the
milling arbour. The unequal spacing of the inserts provides
additional stability and smooth running. The coolant is supplied
axially directly via the milling arbor. The whole milling
cutter is basically a hollow body with a large chamber in the
center, from where the coolant is conveyed to each insert. The
coolant outlets are designed variably. By changing a threaded
pin, the operator can regulate the flow rate for each individual
cutting edge.
The NeoMill-Titan milling cutter range for
titanium machining with completely newly developed
indexable inserts
MAPAL supplies the shoulder milling cutters for titanium
from stock in diameters from 40 mm to 125 mm. The
shell end face milling cutters are stocked from a diameter of
32 mm to 80 mm. Special dimensions are also available upon
request.
further information: www.mapal.com
no. 2, May 2022
13

materials & tools
LACH DIAMANT looks back on 100 years – 12 th part
Poly – poly – or what?
Efficiency concept for re-sharpening all
dia tools (PCD) for the wood, furniture
and composite industry
Example of a diamond
end mill with extreme axis angle
In times like these, a reliable and prompt service
is particularly important – resources must be saved,
stock-keeping must be kept as manageable as possible.
LACH DIAMANT, the global pioneer of diamond
tools for the wood, furniture and composite industries,
has extensive know-how in the development, production
and application of polycrystalline diamond tools
since 1973.
In the beginning, there was a single PCD cutting edge, soldered
onto a holding device, and polished with diamond
grinding wheels – a design based on the classic turning tool.
Initially, rotating diamond tools, such as milling cutters
and saws, were out of the question – high machining times,
i.e. grinding and sharpening times – opposed any commercial
use.
LACH DIAMANT developed an overall service and userfriendly
precision steel grinding machine for the grinding of
the first single-tipped PCD (and CBN) turning tools in cooperation
with a grinding wheel manufacturer. To this day,
it is still built and sold as type PCD-100 and type PCD-300
grinding machine.
With the development of ever larger PCD blanks by the
established manufacturers, General Electrics and deBeers,
tool manufacturers all over the world experimented with
using this new cutting material, superior to carbide in terms
of abrasiveness, also for milling and cutting tasks.
LACH DIAMANT achieved a breakthrough with my idea
to use electric sparks for the electro-erosive machining of
the conductive structure of polycrystalline diamonds (filed
for patent registration in 1978); apart from grinding with
diamond wheels, up to this point the diamond particles/
layers, pressed onto carbide carriers under pressure and heat,
had to be segmented in an elaborate process using diamond
cutting discs.
This discovery – the use of spark erosion for manufacturing
polycrystalline tools – may rightfully be called a moment
of glory for the successful development of high-performance
tools.
Beneficiaries of this new technology were at first mediumsized
wood and furniture manufacturers who immediately
recognized the value of diamond tools for their businesses;
because up to this point, comparative carbide tools had to
be exchanged after every shift by highly-trained specialists.
Inspection of a PCD monoblock milling cutter
Diamond joint milling cutter with extreme axis angles
during sharpening on a «Dia-2200-mini» machine
14 no. 2, May 2022

materials & tools
Precision steel grinding
machine, model
«pcd-100» with rocker
for grinding PCD and
PCBN inserts and
turning steels with
diamond grinding wheel
«Dia-2200-mini», the
universal sharpening machine
for PCD tools
«3Dia Saw Grinder», a
sharpening machine for
diamond saws and chippers
However, diamond tools could be used continuously, without
replacements, and even during 3-shift operations for three to
four months.
The use of spark erosion for forming polycrystalline materials
had been discovered. However, in the early 1970’s only
a limited number of numerically controlled EDM machines
were available, e.g. wire and sinking machines.
LACH DIAMANT designers developed the so-called
LACH EDG ( = Electrical Discharge Grinding) electrical discharge
procedure from the advantages and disadvantages
of both systems – also internally called “spark grinding” by
LACH DIAMANT.
All LACH-EDG machines manufactured at LACH
DIAMANT are not only designed for flexible service tasks
but equally suitable for the production of new diamond tools.
Finally, a very personal remark: “When I hear that the
manufacturers of sharpening machines make good money
with their service,…I have to say that this is not for servicing
our rotation EDG machines… apparently they are too well
designed, how else could it be that, in many cases, the first
service notification for our machines only appears after 10-
20 – in some instances even more – years of daily operation.”
Horst Lach
Today, in 2022, the engineering department at LACH
DIAMANT proudly looks back on 44 years LACH
DIAMANT- EDG electric discharge machines are used all
over the world and provided the business foundation for
many of today’s active manufacturers in the market of diamond
tools for the wood and furniture industries. There is
a reason for my comment towards the diamond tool manufacturers
during recent strolls across Ligna, when I was overheard
saying “These are all my children”.
Today, the LACH DIAMANT EDM programme culminates
in the flexible, universal grinding machine «Dia-2200-
mini» for fast, high-quality service – from diamond end mills
to joint milling cutters – even with extreme axis angles – and
saws with up to 600 mm diameter: tools and saws clamped
together – also suitable for multiple production.
Among other machine models, the unique «3Dia Saw
Grinder» stands out. It was developed for CNC grinding of
diamond saws with up to 750 mm diameter and for all possible
tooth geometries – it also allows for automatic placement
during multiple operation without extensive programming
knowledge.
Presentation of the worldwide first diamond tools
for wood and plastics at Ligna 1979
Note:
More information on this in part 10 of
“Poly – poly – or what? When sparks learned to fly on diamonds”
– special edition from hpt 2021-4.
Free copies are available from LACH DIAMANT via
office@lach-diamant.de or at www.lach-diamant.de
further information: www.lach-diamant.de
no. 2, May 2022
15

materials & tools
Chop saw blade TR-F-K from LEUCO
Long-lasting in non-ferrous metals
For clipping and miter cuts in non-ferrous metals
(NF), there is a new favorite: the HW TR-F-K saw blade
from LEUCO. It achieves exceptional service lives with
impeccable quality. For series production of aluminum
profiles it reduces tooling costs.
The new saw blade is a very good choice for companies that
manufacture aluminum profiles or parts made of other nonferrous
metals on a large scale. It belongs to the LEUCO
topline family of tools, which includes tools of the highest
quality level from this manufacturer. The outstanding
features of this saw blade are the very long tool life of the
carbide-tipped cutting edges in combination with absolutely
burr- and score-free edge quality. This leads to favorable tool
costs, since the saw blade has to be changed comparatively
rarely.
The HW TR-F-K saw blade can be used on cross-cut and
miter saws as well as table saws. It is intended for cutting nonferrous
metals such as aluminum, copper and magnesium.
Wall thicknesses can be up to 5 mm. The saw blade works
particularly efficiently with wall thicknesses of 2 to 3 mm.
The typical application for this saw blade is the cutting of aluminum
profiles. Window and facade manufacturers as well
as machine and equipment manufacturers process such profiles
in large quantities. Manufacturers of materials handling
equipment, linear technology, vehicle trailers and trade fair
structures also use such profiles for their designs.
The HW TR-F-K saw blade cuts non-ferrous metals such as
aluminum, copper and magnesium with wall thicknesses
up to 5 mm
The HW TR-F-K is available in diameters from 350 to
600 mm. With the LEUCO easyFix bore, it can be positioned
very easily on the shaft of circular saws.
further information: www.leuco.com
Automated machine tool loading
Gripping and clamping from a single source
Cobots are perfect helpers. They can be used very
easy and mobile for machine loading and unloading in
the production hall.
They insert raw parts and remove the finished products. In
doing so they relieve employees of monotonous and stressful
tasks and give employees time for other ones. But how do you
get started with automated applications? It is easy with the
new MTB application kits from SCHUNK. The automation
specialist developed three kits specifically for this purpose.
Depending on the space and task at hand, application kits are
available with either single or double grippers. Each includes
one or two universal JGP-P grippers with a blow-off nozzle
and sealed valve box. The “double gripper kit” ensures maximum
productivity as two grippers can load and unload machines
in one operation, resulting in a time saving of almost
50 %. Commissioning is particularly fast and easy. SCHUNK
offers a third application kit for automated stationary workpiece
clamping: the power vise and gripper are combined
in one kit and comming from a single source. Including the
compact and low-maintenance PGS3 clamping force block
with valve terminal. Mountable on a machine table via an integrated
flange. Both, gripper and clamping force block can
be easily integrated into the robot control system. Due to the
sealed valve box the convenient product kits are ideally suited
for use in the harsh environment of a cutting machine. The
gripper kit includes an integrated blow-off nozzle and relieves
the operator from stressful tasks: dirt and chips are automatically
removed from the power vise and workpiece. No longer
manual removal with compressed air, and the clamping areas
are perfectly cleaned for repeatable clamping. The application
kits are available for OMRON, Universal Robots, TM,
Doosan, and FANUC cobots. With specific cables, hoses and
the individual robot connection kits, users can connect the
components from SCHUNK to the cobot in just a few steps
and the machine is ready for automated machine loading and
unloading.
further information: www.schunk.com
C
M
Y
CM
MY
CY
CMY
K
16 no. 2, May 2022

news & facts
Platinum Tooling releases new catalog
Platinum Tooling Technologies, Inc., the exclusive
North American importer of standard and custom live
tools, angle heads, and multiple spindle tools manufactured
by heimatec GmbH, is excited to announce the
release of their new catalog.
The newly released catalog offers an updated look and features
their high quality machine tool accessory lines, including:
heimatec GmbH – live tools and machining center angle
heads; tecnicrafts industries – collets & guide bushings
for swiss type CNC lathes; Henninger GmbH u. Co. KG – mechanical,
air & motor speeders, plus custom machining center
angle heads; Andreas Maier GmbH & Co. KG (AMF) – cleaning
& marking tools.
Preben Hansen, president of Platinum Tooling, is known
throughout the industry for his expertise and experience in
the tooling industry. Hansen will continue to offer advice and
welcomes the opportunity to discuss your application.
Platinum Tooling Technologies, Inc., is located in Prospect
Heights, Illinois (just outside of Chicago). They recently
expanded their facility to provide increased inventory to
better serve the marketplace.
ai165035598913_ANCA_GCX_AD_hp tooling_210x146.5mm_2022.pdf 1 19/04/2022 6:13:12 PM
further information: www.platinumtooling.com
GCX LINEAR:
GEAR UP FOR SKIVING
The GCX Linear provides a complete solution for customers to tap into this rapidly developing
market, including the ability to produce skiving cutters, shaper cutters and regrinding of hobs.
It offers advanced stand-alone software to design and optimise the tool, neatly interfaced with
the gear tool package inside ANCA’s renowned ToolRoom software.
Stuttgart, 17-20.05.2022
Stand C51, Hall 10

news & facts
Combined competencies in the Indian market
C. R. Sudheendra,
former president of UNITED GRINDING India
Ghanshyam Agrawal,
managing director Francis Klein
The UNITED GRINDING Group, one of the world’s
leading machine tool manufacturers, and its longstanding
partner company in the Indian market,
Francis Klein, are pooling their expertise in a joint
venture.
The UNITED GRINDING Group’s commitment in India
has a history: since 2007 the group has been represented by
its own branch office in Bangalore. Francis Klein has been
firmly rooted in the Indian market with the distribution
and manufacturing of high-precision machines for almost
seventy years. The two companies have enjoyed a trusting
partnership for many years, providing their Indian
customers with advice, sales and service of UNITED
GRINDING Group precision machines for grinding, eroding,
laser and measuring. In order to intensify their market
activities and provide even better support to their broad customer
base, the two companies have founded a joint venture,
UNITED GRINDING INDIA LLP. The joint venture, based
in Bangalore, is headed by C. R. Sudheendra, former president
of UNITED GRINDING India branch Office.
“Our goal is to make our customers even more successful.
We are convinced that we will achieve this goal even
better in the Indian market with the joint venture” says
Stephan Nell, CEO of the UNITED GRINDING Group.
“With Francis Klein, we have a strong partner at our side
who shares our demand for quality and our understanding of
service. Together, for the benefit of our clienteles, we will
bundle our competencies, be present even more powerfully
in the market, intensify our sales and service activities, and
be able to be on site with our customers even faster.” Nell continues,
“I would like to take this opportunity to thank Francis
Klein for the trusting cooperation over the past years. I am
convinced that together we will positively shape the future of
the Indian machine tool industry.”
“Francis Klein has been associated with the UNITED
GRINDING Group for decades and this joint venture
is the fruitful culmination of our trusted relationship. The
UNITED GRINDING Group offers customers the absolute
state of the art technology and long-term oriented partnership,
which is exactly what Francis Klein stands for. Through
the joint venture, we will be able to further expand our
prominent market position in the Indian market, will work
to enhance competence in India to better serve our customers
and offer our customers the best possible support” says
Ghanshyam Agrawal, managing director at Francis Klein. “I
would like to thank UNITED GRINDING for choosing to
extend our partnership.”
further information: www.grinding.ch
18 no. 2, May 2022

news & facts
QR code –
the digital link
with added value
The QR code on the packaging of the
EMUGE tap Enorm 1-Z-PM links
directly to the product page
EMUGE-FRANKEN use the QR codes on the packaging
of the tools to offer a digital linking of product information
and thus create productive added value for
users.
The new QR codes on the packaging of EMUGE-FRANKEN’s
threading and milling tools enable customers to view all the
information relating to the purchased item in the web shop in
an instant. Precise cutting values for each threading or milling
tool can be calculated and technical information can be
accessed. The information provided also includes the technical
documentation of the article and, in the case of milling
tools, CAM data for further use in simulation or process
tools after entering requested parameters.
further information: www.emuge-franken.com
The QR codes on EMUGE-FRANKEN’s packaging offer
the digital linking of product information
Swiss Precision Gear Grinding
Visit us at booth
no. D44 in Hall 10
ARGUS-Eyed Focus
on the Grinding Process
Threaded
Grinding
Diamond
Dressing Disc
Clamping
Device

news & facts
CERATIZIT acquires remaining shares
in Stadler Metalle
Gabriele Stadler (left) with Melissa Albeck, CERATIZIT executive board member
CERATIZIT S.A. took over the remaining 50 % of
shares in Stadler Metalle on March 1, and will thus
become the sole owner of the company, which specialises
in the trading and processing of secondary
raw materials. For CERATIZIT, which belongs to the
Austrian Plansee Group, Stadler Metalle is already the
most important supplier of secondary raw materials
for the production of tungsten and tungsten carbide
powders.
For the CERATIZIT Group, the investment in Stadler at
the beginning of 2019 was an important step, as executive
board spokesman Andreas Lackner explains: “Stadler Metalle
has become an important building block in our raw material
supply chain over the past three years, and has helped us to
become independent of raw materials from China and crisis
regions.” The Group is now drawing its supply of primary
raw materials, still necessary from a technological angle,
exclusively from certified western mines.
Good for sustainability:
83 % of raw materials come from recycling
The use of secondary raw materials from recycling not only
helps to secure the supply chain, it is also sustainable. “The
recycling of used cemented carbide requires 75 % less energy
than the processing of ore. In addition, the detrimental
effects on nature of intensive mining are avoided,” Andreas
Lackner adds.
Change in Stadler management
The current managing director and founder of Stadler Metalle,
Mrs. Gabriele Stadler, officially retired February 28, together
with her husband, Mr. Hubert Stadler. “We would like to
express our sincere thanks to Mrs. Stadler and Mr. Stadler.
They have led and developed the company very successfully
over the years, and helped to facilitate a smooth integration
into the CERATIZIT Group,” says executive board member
Melissa Albeck.
Mr. Thomas Wenger took over the management of Stadler
from March 1, 2022. Since 2010 he has been working in purchasing
and sales at Stadler Metalle, the previous 10 years in
strategic purchasing at two other companies in the tungsten
industry.
further information: www.ceratizit.com
20 no. 2, May 2022

news & facts
Machine tool builder
defies global crisis
Currently two-digit growth rates
are scarce to find among machine
tool builders. However, this is what
Kern Microtechnik achieved in
2020 and 2021.
Kern Microtechnik has been growing
steadily – even the past two years were
successful, despite the crisis. In 2020
and 2021 the operational output went
up by 15 % to more than 40 m €. The
machine tool builder and shop keeper
employs approximately 240 employees
on two sites.
Based on current numbers, CEO
Simon Eickholt believes that 2022
will also be successful for Kern: “We
will keep on expanding and we are
very positive that we will grow considerably.”
Such a development is not a given,
even for an in no va tive company such
as Kern, emphasizes Eickholt: “The reason
for our ongoing success is not only
because of the innovative technical
details of our products but much
rather because of the know-how and
determination of our em ployees. As a
company operated by the owners longterm
planning and sustainability was
always a focus for us. This helps us now
to deal with limiting factors imposed
on us by the global market, for example
market uncertainties, shortage of staff
and supply bottlenecks.”
Simon Eickholt,
CEO of Kern Microtechnik GmbH,
is looking back on successful years
and expects to keep on growingthis
year
visit us at:
hall 9, booth 9C40
further information:
www.kern-microtechnik.com

news & facts
HANZA celebrates grand opening of new plant in Estonia
HANZA Holding AB (publ) officially opens its new production facility in
Tartu, Estonia. The new plant strengthens HANZA’s position as a unique
supplier of regional and complete manufacturing and creates additional
capacity for further growth.
In December 2020, HANZA announced that the company would build a new
production plant during 2021, to be opened during the first quarter of 2022. The
factory is now completed and constitutes an important part of HANZA’s expansion
strategy. HANZA’s chairman of the board, Francesco Franzé, leads the opening
ceremony together with the ambassador of Sweden in Estonia, H.E. Ms. Ingrid
Tersman and the mayor of Tartu county, Jarno Laur. “This is an important milestone
in HANZA’s development,” says Francesco Franzé, chairman of the board
of HANZA. “A new, modern facility in Estonia, tailormade for complex assembly,
creates a strong foundation for continued rapid growth.”
“We experience more and more companies suffering from disruptions in the supply
chain,” says Erik Stenfors, CEO, HANZA. “We provide an alternative through
complete and local manufacturing, which does not only create a more reliable
supply-chain, but also increased flexibility and lower cost.”
“With both parts production and final assembly in the same area, we reduce our
carbon footprint,” says Emöke Sogenbits, president cluster Baltics. “To create an
optimal manufacturing flow, we have built the new plant directly adjacent to our
existing facility for sheet metal production.”
The investment in the new plant of 12,000 m 2 amounts to approximately SEK
80 million. The opening was celebrated in March with HANZA colleagues, customers,
suppliers as well as local authorities and partners.
further information: www.hanza.com
New Managing Director at BENZ
The focus is on long-term corporate goals
As of March 1, Martin Schreiber, a graduate engineer and previously
regional CEO & president industrial Asia Pacific at Schaeffler, took over
the management of BENZ, the Baden-Wuerttemberg-based specialist
for CNC aggregate technology.
BENZ manufactures tool systems and machine technology for all industries and
is one of the world’s leading manufacturers and suppliers of components and systems
for tool and machine technology. The company is part of Schenck’s Measuring
and Process Systems Division (MPS) of the global technology group Dürr AG.
“I am highly motivated and looking forward to the new challenges at BENZ. I
have complete confidence in the know-how and potential of BENZ and my new
committed colleagues,” says Martin Schreiber.
Jörg Brunke, CEO of the MPS Division, is also looking forward to working with
the new managing director at BENZ: “With Martin Schreiber, who already knows
the market and customers in Asia very well, we are now able to take BENZ a big
step further in the direction of growth and internationalization and thus accelerate
the implementation of our strategy. In addition, as a member of the MPS executive
group, Mr. Schreiber will make important contributions to the globalization
of MPS.”
Extensive experience in the Asian region
As a medium-sized and internationally operating company, BENZ would like to
grow further and open up new markets for mechanical engineering solutions in the
Asian region. It is exactly for this purpose that Martin Schreiber will contribute his
extensive experience in the Asian market for daily practice: due to his diverse roles
and projects in the Asian region, he knows the needs, opportunities and challenges
of the Asian market as well as the perspective of the end customers.
New managing director Martin Schreiber
After several previous positions with
Asia responsibility at Schaeffler, Martin
Schreiber held the overall responsibility
for the management of the industrial
business in the APAC region as “Regional
CEO & president” from 2018. In
this position, he succeeded in achieving
profitable revenue growth within two
years and in establishing a new aerospace
MRO service hub in Singapore.
In addition, Mr. Schreiber successfully
established a new “green field” plant for
Schaeffler in Vietnam.
information: www.benztooling.com
22 no. 2, May 2022

fairs
news & facts
European branch of the World Tool and Die Association
elects new chairman
Markus Heseding
With Markus Heseding, managing director of VDMA
Präzisionswerkzeuge, Germany took over the presidency
of ISTMA Europe.
He succeeds Joaquim Menezes, owner of Iberomoldes, on
behalf of CEFAMOL (Portugal), who has last chaired the European
branch of the world association with great commitment
since 2017.
Heseding also joined the Board of Directors of ISTMA
World in 2017 and said after his election on Thursday: “Tooling
is the basis of vast parts of the industrial production in
Europe. The sector is suffering from a lack of young talents
and a creeping withdrawal of companies from the increasingly
difficult tool and die business. Therefore, we must ensure
that this highly attractive key sector becomes more present
in public perception.” Heseding is also committed to efficient
and fair cooperation along supply chains.
ISTMA is an international association representing 30
special tooling and machining associations throughout the
world. Collectively, ISTMA member associations represent
over 8,000 companies and over $40 billion U.S. dollars in annual
sales. ISTMA World is in charge of the central coordination
and organization of all international activities. ISTMA
Europe coordinates the activities of the European member
associations.
information: www.istma.org
TIMTOS x TMTS 2022
Physical exhibition ends successfully
TIMTOS x TMTS 2022, the first co-branded machine
tool mega show in Taiwan, closed with huge success.
The show has attracted more than 40,000 online
and offline visitors at home and abroad. Notably, the
online exhibition has reached visitors from more than
20 countries/regions.
With 950 exhibitors in 5,100 booths, TIMTOS x TMTS is
not only the largest trade show in Taiwan since the outbreak
of the pandemic but also the world’s first machine tool mega
show in 2022. In response to border controls, the show featured
an array of online services for international visitors
and media, including “On-site Guide for Online Visitors”,
“Sourcing Taiwan Machinery”, “On-site Guide for Media
Tour”, “Live Tour @ Showground”, “Media Eye on TIMTOS x
TMTS”, “Podcast Live” and TIMTOS x TMTS Online.
Processing machines, multi-axis machining centers and
laser cutting machines were amongst the most sought after
items for foreign buyers.
The machine tool industry keeps up with the development
of future trends and accelerates digital transformation and
upgrades. New models and solutions have targeted emerging
business in sectors such as semiconductors, green energy,
electric vehicles, health care and aerospace. This year’s
TIMTOS x TMTS welcomed a wide spectrum of visitors
from different industries. TIMTOS is scheduled to return in
March 2023.
further information: www.tmts.tw
no. 2, May 2022
23

processes
Software thought backwards
From the desired gear to the perfect skiving tool
There is already an infinite number of different gear
geometries. Nevertheless, engineers are constantly
coming up with new variants. For example, gears
are becoming smaller, more complex and lighter. At
the same time the demand for performance – quiet,
smooth operation, even under highest load – is always
higher. The variety of gears knows no limits, but highprecision
manufacturing does.
Today, the desired geometry of a gear is often achieved by
skiving. This means the precision of the gear is limited by the
precision of the tool. The principle of skiving has been known
for over a hundred years, but the technology in mechanical
engineering has only been able to perform skiving reliably
since a few years. The previously desired precision of the tools
and thus of the skiving process was achieved in elaborate development
steps. “Just a few years ago, the quality of gears in
class 4 to 6 was the measure of all things. Today, tolerances
of 2 µ are not uncommon.” For software manager Wolfram
Hermle of Haas Schleifmaschinen, the time was ripe to take
a very fundamental look at this issue in order to search for a
groundbreaking solution.
In a high-precision gearbox, exact timing is everything.
The cylindrical gears must mesh one hundred percent. Flank
shape and helix angle do not allow any tolerances, and this
Wolfram Hermle:
where previously quality 4 to 6 was the benchmark for
gears, we are now aiming for a quality of 2 to 3
applies to both internal and external geometries. The manufacturing
of such complex profiles requires highly sophisticated
calculations. In the profile accuracy or the pitch accuracy
of the gears, the smallest error continues and leads to
Multigrind® Styx: the image of a skiving tool does not capture how complex the calculation of its geometry actually is
24 no. 2, May 2022

processes
Haas Schleifmaschinen: the picture shows the white contact point between the tool and the workpiece
inaccuracies in the entire gear unit. Often, when the gearbox
is prototyped, it is not even apparent where exactly the error
is hiding. Therefore it was time for the engineers at Haas
Schleifmaschinen to come up with a solution.
“On the market, there was no satisfactory calculation
model for ever increasing precision requirements.” Wolfram
Hermle describes the situation two years ago when he initiated
the project in the development of the Multigrind® software.
The goal was to create a calculation basis that is able
to cope with the unbelievable variety of gears. And this with
a precision that opens up new horizons for gear manufac -
turers. Derived from the perfect geometry of a cylindrical
gear, the calculation is based on the geometry of the skiving
tool. The motion sequences in production and the relative
speed of the flanks define the future geometry of the
respective generating skiving tool. “We calculate with
the exact path resulting from the movement of the gear.”
Wolfram Hermle does not want to be more specific about
this, because after all, this calculation model is a new development
from Haas Schleifmaschinen that is causing a lot of
excitement in the market with its unique position.
The desired grinding paths are created on the calculated
surfaces in longitudinal, transverse and trochoidal paths.
The contact point between tool and workpiece can thereby
move on the grinding wheel profile. This shortens the grinding
paths and thus the grinding time. Standard grinding
wheels are used for this application. This eliminates the need
to purchase expensive form grinding wheels.
However, the new calculation model is only one side of the
coin. The other is implementation. Because precise software
requires equally precise coordination with precise hardware.
The exact transfer of the Multigrind® Horizon software to the
machine movement does not allow any deviations. To generate
this precision, the alignment of the grinding wheel must
be accurate to one ten-thousandth of a degree.
Measuring, dressing, grinding,
measuring, dressing, grinding…
The desired grinding performance cannot be achieved without
sophisticated measurement technology and frequent
dressing of the grinding tools. The desired accuracy of
the skiving tool and subsequently of the gear can only be
achieved if all production steps are coordinated with each
other in a collaborative process. The results of the permanent
re-measurement with subsequent compensation of errors
are the basis for the fine correction of the grinding
path. This automatic process takes place entirely in the sense
of a closed loop. In this way, the quality remains constant
and error-free – workpiece for workpiece. The Multigrind®
Horizon software handles this production sequence reliably
and quickly, even in unmanned operation.
Wolfram Hermle comments: “As far as I know, this level
of precision can only be achieved within the Haas
Schleifmaschinen cosmos. Only when software and hardware
are perfectly matched to each other the perfect tool can
be created for manufacturing a perfect gear. At Haas, we specialize
in developing from the desired end product. The question
‘What properties should the gear have?’ becomes the
starting point of our manufacturing strategy for the perfect
skiving tool.”
further information: www.multigrind.com
no. 2, May 2022
25

processes
Sharpening skiving cutters for new EV transmissions
Enable skiving cutter sharpening on ANCA’s TX and MX machines
Fossil-fuelled cars are set to become a part of history.
Many countries have set a deadline for ending the
sales of fossil-fuelled cars: France from 2040 on, the
UK by 2030 and Norway aims to become the world’s
first country to achieve this by 2025.
Responding to green initiatives, and after billions of dollars
have been invested in vehicle electrification, the automotive
industry’s giants are pledging to stop making old fashioned
internal combustion engine (ICE) vehicles. Volkswagen plans
for 25 % of sales to consist of electric cars by 2025, Progressive
General Motors is aspiring to stop making gasoline-powered
vehicles by 2035, and Ford (Europe division) will go entirely
electric by 2030.
For cutting tool manufacturers serving the automotive
industry, the industry’s electrification is an existential challenge
and a revolutionary opportunity. In 2017, 11.8 % of cutting
tool consumption was for automotive manufacturing.
Machining time for pure electric vehicles (EVs) is estimated
to reduce by 50-75 % compared to traditional ICEs, resulting
in overall cutting tool consumption decline as ICE vehicles’
production ceases.
grinding can easily cater to. The problem is with the internal
ring gear. Traditionally, the internal gears are produced with
shaping or broaching; shaping is slow, while broaching relies
on cumbersome tooling.
For EV, efficiency – as well as noise emission – is of much
higher priority for customers. Gears for EV require greater
precision and higher performance. The quality needs to increase
from DIN 10 to DIN 6 for the internal gears; the gear
industry sees hard skiving as the revolutionary process to
produce the millions of internal ring gears needed for EV.
Driven by EV’s unparallel 28 % ~ 36 % growth rate (see
chart), the skiving cutter used in the skiving process is in
high demand. Due to its complex geometry, producing
solid carbide skiving cutters requires a series of technology
and process development. Released in 2019, ANCA’s GCX
Linear provides a complete solution for manufacturing
DIN AA quality solid carbide skiving cutters – the highest in
the industry.
The declining demand for cutting tools is a substantial
threat, especially for cutting tool makers that heavily depend
on the car industry; but EV also provides many opportunities.
The new skiving cutters required for the internal gears
used in many new EV transmissions are significant.
illu 1
45 % of all gear production is for vehicle transmission. EV
has changed the requirement for the gear industry. The high
engine speed of up to 20,000 rpm means a higher gear ratio is
required to reduce the speed for efficiency. The planetary gear
system is more prevalent in the new transmission design. In
a planetary gear set, the external gears need to be ground,
which the current production process of hobbing and then
Skiving cutters are classified as a pinion cutter, consisting
of the flank and rake face. After the flanks are produced,
resharpening – or simply sharpening, as known in the industry
– only grind back the rake face. These tools are expensive
and designed to have a long tool life, typically 6 to 10 mm of
resharpenable depth. During resharpening, the rake face is
ground back by 0.3 to 0.5 mm each time, depending on the
level of damage. There can be as many as 30 to 50 resharpenings
during the lifetime of a tool. Following the growing
trend of EV, there could be a need for hundred of thousands
of skiving cutters by 2024, which will equate to over a million
sharpenings.
To enable ANCA customers to tap into this fast growing
market, ANCA released a new software package to sharpen
skiving cutters and shaper cutters. Customers with MX and
TX machines only need to purchase a software update and
replace the standard probe with a ruby probe tip.
26 no. 2, May 2022

processes
Conical rake face resharpening with 1A1 wheel
In the ToolRoom software package, the new purchase
option “Pinion type cutter sharpening” contains operations
for digitising and sharpening of the two rake face styles:
stepped rake face and conical rake face. (illu above)
A conical rake face is part of a conical surface, defined by a
rake angle and intersection with the flank to form the tool’s
cutting edge. Sharpening a conical rake face requires an operation
to digitise the end of the tool position, then regrind
the conical surface with a 1A1 wheel (illu top right). There is
a plunge grinding method for the initial heavy grinding and
oscillating grinding styles for subsequential resharpenings.
A stepped rake face is a planar surface defined by a rake angle
and a lead angle. To resharpen stepped rake face, finding
the tooth’s accurate index position and aligning with it is critical.
ANCA software calculates the correct geometry to guide
the ruby probe to find the right position. The process is automated,
with no need for particular alignment and manual
intervention. The sharpening of the rake face plane takes
place on one tooth at a time, either with a 1A1 wheel for speed
(illu lower right) or a cup wheel for improved surface finish.
The resharpening package is available for MX and TX
machines. With minimal hardware change, the MX can accommodate
for tool diameters up to 105 mm. The TX is even
Resharpening of stepped rake face with 1A1 wheel
more capable, with a larger working envelope and more
robust build, to fit a tool diameter up to 240 mm. The hub
type and disk type cutters can be mounted onto the collet
with a fixture. The shank type cutters can be clamped
directly in the collet or with an adaptor for morse taper.
This package is also a desirable solution for gear manufacturers
wanting to resharpen these tools regularly in-house.
further information: www.anca.com
no. 2, May 2022
27

processes
Smart savings through efficient process control
Spotlight on energy and resource consumption
at GrindingHub
Even before the start of the Russia-Ukraine war,
rising energy costs were putting pressure on the manufacturing
sector. Germany has long had the highest
prices for industrial electricity in Europe. At the same
time, all companies are being called upon to reduce
their carbon emissions significantly and ensure that
their production is resource-efficient.
Grinding is no exception here. Industry experts are actively
looking at how to reduce energy and resource consumption
all along the process chain – including at the recent
digital “Schleiftagung” grinding conference of the
Laboratory for Machine Tools and Production Engineering
(WZL) of RWTH Aachen University and at GrindingHub
trade show in Stuttgart, May.
Rising energy and raw material costs, legal regulations
and extended customer requirements are all significant factors
which are increasing the importance of energy effi -
ciency in grinding. Within the process chain, grinding is
considered an energy-intensive manufacturing process, since
comparatively small workpiece volumes are machined at
relatively high cost. However, LCA improvements are anything
but trivial, and can often only be achieved in small
steps or on the periphery of the production operation itself.
Thinking beyond the grinding process
Prof. Thomas Bergs, executive director of the WZL and member
of the WGP (German Academic Association for Production
Technology) introduced a further aspect in his presentation
at the grinding conference. He pointed out that grinding
technology can make a significantly greater contribution
to climate protection and resource conservation if companies
are prepared to think beyond the actual grinding process.
Improving the CO 2 -optimized design of the grinding process
also includes considering a better function of the component
in use. More efficient process control leads to reduced use of
resources not only in the manufacturing, but also in the service
phase of the workpiece by ensuring longer service lives
and improved functional properties. This requires recording
the use of energy and resources for each component in digitally
networked production.
Thomas Bader
Christoph Müller
28 no. 2, May 2022

processes
For Thomas Bader, managing director of Haas
Schleifmaschinen GmbH in Trossingen, Baden-Württemberg,
improving energy and resource efficiency therefore starts
long before the actual grinding process: it begins in the selection
of appropriate materials for the construction of the
machines. In its Multigrind machines, for example, Haas has
opted for a mineral cast machine bed which not only uses
30 % less energy in production, but is also particularly durable
and easily recyclable. In addition, mineral cast beds offer
excellent vibration damping, which increases the service
life of tools. If tools – in this case grinding wheels – have to be
dressed less frequently, this has a positive effect on the energy
footprint, says Bader.
Recyclability plays a major role in machine design, emphasizes
the Haas manager, as do the requirements of the european
RoHS Directive for electrical and electronic equipment.
This stipulates that every component must be subjected to a
risk assessment for environmentally hazardous substances.
“Smart savings” is the watchword when it comes to measures
that help reduce energy consumption in machines, says
Thomas Bader.
Machines, grinding oils and grinding wheels
There are numerous examples of effective measures. Bader
cites energy recovery modules which recuperate the energy
of the NC-axes and grinding spindles during braking,
and the use of economical synchronous motors. Haas
Schleifmaschinen also makes use of the intelligent Ecomodus
standby concept. This is based on software that reduces
power consumption in standby mode by a further 70 %. The
grinding machine manufacturer is also dedicated to minimizing
the use of lubricants. For example, the company’s own
linear axes rely on the use of economical grease lubrication
instead of oil mist. The supply of energy-optimized cooling
lubricant (coolant) is provided in a controlled pump operation
using 3D coolant shaped nozzles specifically adapted to
the workpiece.
The ways in which coolants and grinding oils can influence
energy efficiency in the grinding process are explained
by Ken Bausch, grinding oil expert at oelheld GmbH. The
Ken Bausch
Eco change system, Dr. Kaiser GmbH & Co. KG
company is committed to sustainability in the development of
its products, production processes and its use of resources – as
expressed through its own Hutec (Human Technology) brand
for humans, nature and machines. The Stuttgart-based company
decided at an early stage to purchase its own machines,
which would allow it to carry out test series by itself. Analysis
and testing equipment can now be used to determine the
optimum type of oil based on a finely tuned ratio of viscosity
and additives for every machine type and every grinding
process, says Bausch. The results include not only long service
lives and low refill quantities for the oils, but also quiet,
smooth and easy running of machines, which is indispensable
for achieving fast machining, low tool wear, superior
surface qualities and economical power consumption. “We
are meeting very clearly expressed customer demands here,”
says Bausch.
New materials posing new challenges
According to Bausch, these new and in some cases exotic
materials that have to be processed will present major challenges
in the future – and thus new tasks for the research and
development department at oelheld. “We are gliding into new
areas together with the machine manufacturers,” says the
expert. He is also expecting to receive corresponding inquiries
at GrindingHub. Furthermore, oelheld is cultivating
partnerships with universities and research institutes in response
to ever new technological requirements.
Similarly, the trend toward high-strength materials which
are difficult to machine is likely to frustrate efforts to increase
energy and resource efficiency, especially given the simultaneous
calls for process-reliable manufacturing plants capable
of 24/7 production. “The only way to improve energy
efficiency in the grinding process is to find a perfect match
between the machine, workpiece, grinding wheel, dressing
tool, dressing spindle and cooling medium,” says Christoph
Müller, head of Application Technology at Dr. Kaiser
Diamantwerkzeuge GmbH & Co. KG, system provider for
no. 2, May 2022
29

processes
Haas Schleifmaschinen
grinding technology, based in Celle, Lower Saxony. As a
rule, the customer’s primary focus is on the component
being manufactured, he says. The process of dressing the
grinding wheel responsible for carrying out the actual manufacturing
process is regarded as non-productive time. Thus
the experts at Dr. Kaiser have the task of conditioning (profiling
and sharpening) the grinding wheel in the shortest possible
space of time.
Individual limits for process optimization
During process optimization, all parameters, especially cutting
speed and feed rates, must be optimized before the
dressing tool can be adjusted accordingly. However, it should
be kept in mind, says Müller, that each production machine
has its own physical limits within the process. Here, he says,
it is often necessary to rely on empirical values. Nevertheless,
about 80 % of the optimization potential can be determined
by making prior process calculations.
The grinding
wheel itself offers
optimization potential
in terms
of cycle time, as it
can be trimmed
not only for faster
grinding but also
for a longer tool
life. After the unavoidable
dressing
process to condition
the grinding
wheel, it will be
able to grind stably
longer and create
more workpieces
until it needs to
be dressed again
due to grinding
wheel wear, abrasion,
clog ging or
loss of shape. According
to Müller,
Dr. Kaiser is
making a contribution
to sustainability
with its in-house ECO change system, which will also
be on display at GrindingHub. Here, the carrier unit can be
used several times; only the diamond coating (which wears
out over time in the dressing process) is replaced. This saves
more than 80 % of material and energy compared to conventionally
manufactured dressing tools.
Durability is key factor in resource conservation
For grinding oil manufacturer oelheld, improving energy efficiency
involves creating durable products, ensuring superior
quality levels and using high-grade raw materials, emphasizes
Ken Bausch. Durability is also the key to resource-saving
production for Thomas Bader, managing director of Haas
Schleifmaschinen. For him it is vital to ensure that the manufacture
and use of the company’s Multigrind machines are
as environment friendly as possible. This includes advising
customers on how to obtain the longest possible use of their
machines. A lifetime of 30 years is not unrealistic, he says.
“It often makes more ecological sense to give machines that
are not in continuous use a general overhaul with new components
and thus breathe a second life into them than to
advise customers to buy new equipment,” Bader notes.
At GrindingHub Haas Schleifmaschinen will present its
first ever Multigrind system in which the machine and control
are completely separate. The machine is controlled via
a tablet which can be replaced if the operating system is no
longer receiving updates or if a fault develops. In this way,
machines can continue to offer a long service life even in
these times of fast-moving digitalization and increased
networking. It is important to think beyond the grinding
process itself.
oelheld storehouse
further information: www.grindinghub.de
30 no. 2, May 2022

processes
Sustainable investment in coating technology
The tiger leap with HiPIMS in Southeast Asia
In India and Southeast Asia, the machining
sector is growing steadily, and high-performance
precision tools are in hot demand. With CemeCon’s
coating technology, more and more tool manufacturers
are gaining competitive advantages there.
Thailand, Indonesia, Singapore, Malaysia, Vietnam –
Southeast Asia, home to more than 650 million people, is developing
rapidly. “Alongside India, the ASEAN countries are
among the most promising markets. The economic upswing
there is tangible. Now with the end of the pandemic, I see
great opportunities,” says Manish Adwani, managing director
of the newly founded Indian CemeCon subsidiary, which has
been serving CemeCon customers in India for a long time
in close cooperation with Würselen.
After intensive planning CemeCon is now pleased to announce
the new establishment of the Indian subsidiary
CemeCon Coating Pvt. Ltd. in Pune. The new managing
director is Manish Adwani, a long-standing CemeCon sales
partner and profound expert of the Indian and Southeast
Asian market. In addition to sales, the service team supports
customers in the region online and also on-site. In addition
the Indian branch has an extensive spare parts warehouse.
With the foundation of CemeCon Coating Pvt. Ltd. the coating
experts take into account the enormous importance of
the region.
Securing competitive advantages with HiPIMS
Manish Adwani: “Especially for medium-sized tool manufacturers,
our coating technology is a sustainable investment to
secure competitive advantages, as for example in India: with
a new HiPIMS Turnkey project, Accusharp Cutting Tools Pvt.
Ltd. in Pune underlines with HiPIMS its role as innovation
leader. Word of this success has also spread in Southeast Asia,
and we have been able to convince new partners of our premium
coatings.”
Accusharp Cutting Tools Pvt. Ltd., based in Pune, India,
develops and manufactures special cutting tools for a
wide range of industries. With the CC800® HiPIMS installed
in November 2021, the tool manufacturer can significantly
increase the performance of its tools. For steel machining
FerroCon® supplies the appropriate coating material for excellent
tools “Made in India”. After all, the world’s largest
steel manufacturer is based in India.
From training to installation everything online
Always and everywhere online – all is digitally networked in
particular in this region of the world. For example, the entire
commissioning of the coating systems at WPP Engineering,
Thailand and Geswinn Indonesia was also carried out online.
Manish Adwani: “The intensive on-site training at the
world’s largest
coat ing center in
Würselen is an
essential part of
our quality and
service promise.
We ful fill this
on line just as
we do with faceto-
face training.
For this the
CemeCon team
threw itself into
the new task
with passion and
Manish Adwani,
presen ted fascina
ting new so-
new Indian subsidiary
managing director of CemCon’s
lutions.” During
the online installation CemeCon’s experts guide the customer
technicians live via video streaming step by step through the
process and explain all the details of the technology. In principle
this is similar to an online live batch: there CemeCon
shows tool manufacturers in a 1-to-1 dialog what is possible
today in the coating of precision tools and how easy it is to
handle the systems.
In Thailand, CemeCon recently installed the first CC800®
HiPIMS coating system, at WPP Engineering Co., Ltd. WPP
is deeply rooted in the tool making world there since the
company is offering tool grinding machines from a premium
manufacturer. With the HiPIMS coating technology customers
in Thailand and Vietnam now receive complete solutions
for the production of cutting tools from a single source.
In Indonesia – the country with the fourth largest population
worldwide – CV Geswinn Indonesia has successfully
launched a coating service near the capital Jakarta with
a newly installed CemeCon coating line. Geswinn is an expert
in tooling solutions and sells cutting tools from wellknown
manufacturers. In addition, the company offers its
own special tools and re-sharpened tools in original quality
with CemeCon coatings.
Service promise kept
“These two examples prove it: We are keeping our promise of
quality and service in these extraordinary times. Our team
has the service gene and always finds a way to the customer.
We offer support at any time for questions about CemeCon
coating technology with the full range of possibilities, via
online diagnostics, with our service hotline or during a visit,”
adds Manish Adwani.
further information: www.cemecon.de
no. 2, May 2022
31

machining center
GrindingHub:
TSCHUDIN puts the focus on versatility
The Swiss grinding machine manufacturer
TSCHUDIN AG will present its versatile product portfolio
at GrindingHub, the new leading exhibition
for grinding technology, which will be held for the
first time in Stuttgart from May 17 to 20, 2022. The
TSCHUDIN booth 9D50 in hall 9 has over 200 m 2 of
concentrated know-how in centerless grinding.
“For the first time we are exhibiting all three machine types
at the same time, thus underlining the wide range of applications.
Workpieces of the most diverse sizes can be ground
on our machines: from the smallest wires for medical technology,
whose shape can only be seen under a magnifying glass,
to truck axles weighing 150 kg,” reports Iwan von Rotz, CEO
of TSCHUDIN AG.
The product portfolio of the technology leader founded in
1947 consists of three different machine types. The compact,
centerless CUBE 350 external cylindrical grinding machine,
which made its debut at EMO in Hanover in 2019, is the
latest innovation. “We developed this patented three-axis
CNC grinding machine specifically for machining small
workpieces up to 20 mm in diameter. The CUBE 350 has a
small footprint and offers maximum efficiency – a real allrounder,”
emphasizes von Rotz.
Automation brings a productivity boost
Due to its innovative appearance and ergonomic design, the
CUBE 350 was awarded the Red Dot Design Prize in 2020.
Like other TSCHUDIN machines, the CUBE 350 can be
equipped with automation solutions that ensure autonomous
operation around the clock and gives users a productivity
boost. Flexible loading and unloading as well as fast changeovers
ensure maximum efficiency.
In combination with a collaborative robot,
the TSCHUDIN CUBE 350 provides users
with a productivity boost
The centerless grinding machines of the
TSCHUDIN 400 ecoLine/proLine series are
optimally suited for machining medium-sized
workpieces with diameters up to 150 mm
Ideal for large workpieces
The other two machine types are the 400 ecoLine/proLine,
which is ideal for machining medium-sized workpieces with
a diameter of up to 150 mm, and the centerless grinding machines
of the 600 ecoLine/proLine, which can also machine
larger workpieces with a diameter of up to 250 mm and a
length of up to 500 mm.
The centerless cylindrical grinding machines from
TSCHUDIN are used in all industries where mechanical
components are required with high precision and at economical
unit costs – from injection technology, hydraulics, automotive
engineering, drive technology, the bearing industry,
medical technology and toolmaking to aerospace. The materials
machined, such as steel, aluminum, glass, titanium, carbon,
ceramics, germanium or silicon, are just as versatile as
the areas of application.
Urs Tschudin, the owner of TSCHUDIN AG, is looking forward
to GrindingHub, the new industry meeting place for
grinding technology: “Our team is looking forward to the exchange
with international industry experts and customers. It
is particularly exciting to be on site at the very first Grinding-
Hub event and to present our innovative machines.”
further information: www.tschudin.swiss
32 no. 2, May 2022

machining center
GrindingHub:
Vollmer launches the 5S campaign
A double premiere in Stuttgart: the first ever
GrindingHub international trade fair for grinding
technology will take place May 17 th , 2022, and
for the first time sharpening specialist VOLLMER
will present its 5S campaign: Sharp, Smart,
Sustainable, Social, Strong.
In booth 7C50, hall 7, visitors can inspect the sharpening
machines, services and digital solutions offered
by the Biberach machine manufacturer. VOLLMER
will be showcasing new tool grinding machines from
its VGrind range as well as new products for machining
carbide-tipped circular saws at the trade fair.
Other highlights at the trade fair will include the VLaser
370 laser machine, the VHybrid 260 grinding and eroding
machine and the digital V@dison solutions.
The five pillars of the 5S campaign
With its new 5S campaign, VOLLMER has established five
pillars to support its product range: Sharp, Smart, Sustainable,
Social, and Strong. VOLLMER grinding, eroding and
laser machines are backed up by smart and digital services,
ensuring maximum sharpness. Thanks to sustainable technologies,
VOLLMER plays its part in environmental sustainability.
Social refers both to the increased importance of
social media platforms such as LinkedIn, Facebook and
YouTube and to the social links between VOLLMER and its
customers, suppliers and employees, as well as its efforts to
support young people. VOLLMER uses events and web seminars
to maintain a strong position as a technology leader
whilst continually improving the efficiency of its machines
and services. Trade fair visitors can figure out all about the
other elements that make VOLLMER an industry leading
machine manufacturer.
Five world premieres and tried-and-tested solutions
GrindingHub 2022 exhibition will also mark the world premiere
of three new VGrind grinding machines, suitable for
machining carbide tools. These new machines apply the
tried-and-tested technology of the VGrind range: they are
also based on the innovative double-spindle concept, which
enables precise and efficient multi-level machining thanks to
its two vertical spindles. By expanding its machine range in
the area of tool machining, VOLLMER can address the individual
needs of its customers more precisely.
VOLLMER has also added two new machines to its range
for grinding circular saw blades. They are ideally suited to
machining tooth faces and tooth tops as well as the flanks
of carbide-tipped saw teeth with a wide range of geometries.
These machines feature intuitive operation, enabling users
to learn sharpening processes almost instantly. They can also
be combined with tried-and-tested VOLLMER automation
solutions for operating around the clock without manual intervention.
Tried-and-tested solutions will also be on display in
Stuttgart. With tools ranging from drills to milling cutters
through to reamers for machining PCD or ultra-hard materials,
the full-line range offered by VOLLMER includes a
wide variety of eroding and laser machines. For instance, the
VOLLMER trade fair boothr will feature the VLaser 370 laser
machine, which enables contact-free machining of cutting
edges thanks to its powerful laser. The VOLLMER QXD 250
eroding machine is likewise designed for contact-free sharpening
of complex PCD rotary tool geometries via spark erosion.
There will also be the VOLLMER VHybrid 260 machine
that offers a complete solution for eroding and grinding operations
in a single machine.
Tangible and digital services
Maintenance, training and finance are at the heart of
VOLLMER services, and these are increasingly digital and
web-based thanks to the V@dison solutions. Software solutions
control sharpening machines and automated processes
and can increase machine performance as required. Smart
solutions are also available for evaluating process data or
cross-connecting users directly with VOLLMER services. For
example, customers can connect to technicians in real-time
via the “Visual Support” V@ guide solution, or access machine
data, information and a spare parts shop online via a
personalised customer portal. The customer profile will be
presented for the first time at GrindingHub and is a personalised
digital window for VOLLMER customers that integrates
the majority of IoT services offered by VOLLMER.
further information: www.vollmer-group.com
no. 2, May 2022
33

machining center
GrindingHub:
Automated laser processing of diamond tools
DMG Mori is a worldwide leading manufacturer of
machine tools. Integrated automation and end-to-end
digitization solutions extend the core business with
turning and milling machines, advanced technolo -
gies and additive manufacturing. With modular products,
DMG Mori enables an easy, fast, scalable entry
into digital manufacturing as well as end-to-end
digitization.
At GrindingHub DMG Mori presents the Lasertec 50
PrecisionTool with PH 50 for automated laser processing of
diamond tools up to Ø 355 mm. With High Speed Mode 3.0 –
210 % faster and 56 % lower unit costs compared to EDM!
Vertical grinding machines from Taiyo Koki for maximum
productivity, highest accuracy and ease of operation and setup.
The CVG-6, up to Ø 600 mm grinding, with two high stability
grinding spindles for internal and external grinding operation,
offset by 180 °, incl. 6-station automatic tool changer
(HSK-E100). Equipped with continuous indexing Turret B-
axis 0.0001 ° positioning and direct drive, full C-axis with
cam grinding function. DMG Mori is present in 87 countries
worldwide – with 16 production plants, 111 sales and service
locations – and is actively advancing the future fields of automation,
digitization and sustainability.
further information: www.dmgmori.com
GrindingHub:
Technology range cutting tool manufacturers
need to remain agile, improve quality and grow capacity
Transforming through innovation with
ANCA’s AIMS: the future factory is efficient, automated
and runs round the clock. It uses modular programs
scripts, remote access, and cutting-edge machines
to operate at maximum efficiency.
The world of CNC machining thrives on innovation. Grinding
machines, cutting tools and software are constantly
evolving to be more efficient, flexible, accurate and automated.
ANCA chases customer requirements to identify the next
challenge to be solved – constantly iterating and refining its
technology. In over 40 plus years of operations, developments
that were considered cutting-edge, are now business as
usual – even at ANCA it is reflected on how revolutionary the
early products felt. Pat Boland, ANCA co-founder and joint
managing director, said: “We can recall a time when it was
almost impossible to resharpen cutting tools on a CNC machine.
That was until 1986, when ANCA launched our TG4,
the first machine in the world to automate the measurement
of tool geometry and regrinding through probing.”
“Or when we introduced the system 32 which, for the first
time, applied advanced robotic software to tool grinding
which enabled significant opportunities, for example, the soft
axis or soft machine kinematics which simplified the grinding
of cutting tools. We’ve come a long way, from probing
Pat Boland
for cutting tools, leading the competition in five-axis grinding
or from simulating grinding processes before grinding
with the CIM3D.”
“Designing the best technology requires a multi-pronged
approach. We immerse ourselves in the market; are continually
inventing; keep a keen eye on new developments and
bring them into our applications. We seek out intelligent,
talented people, and interact with customers daily to understand
their specific needs. This is how we design and manufacture
our market-leading solutions.”
34 no. 2, May 2022

machining center
AutoMarkX
At GrindingHub ANCA will showcase its technology range
that enables customers to grow capacity, improve profit margins
and gain efficiencies. Deciding what technology to invest
in should be driven by business goals, working with existing
objectives, processes, data and ideas.
Launching the
CPX in-process OD measurement system
The CPX in-process OD measurement system is a quality
control system that monitors and controls the OD of ground
blanks within a batch production.
Batch grinding on a CPX with high material removal rates
and to tight tolerances is a basic function of the machine, the
OD measurement system takes it further by utilising the Statistical
Process Control (SPC) feature that comes standard
with the OD measurement software. SPC is user defined, the
tolerances along with the Cp and CpK values are constantly
monitored, controlled, and reported to the user.
The OD measurement system is permanently mounted inside
the machine and only called upon when required, based
on the set tolerances and the frequency of measurement,
an accurate in-process measurement and compensation is
applied to maintain the blank OD to the nominal diameter.
The system is flexible with the ability to handle multiple
diameters in one setup, making it perfect for complex blank
geometries/shapes and longer batch runs.
AIMS detail
LaserUltra
AIMS
ANCA’s Integrated Manufacturing System (AIMS) is the
future of optimised cutting tool production through streamlined
manufacturing and connectivity. With ANCA and
AIMS, customers can achieve continuous, unattended production
that dramatically reduces non-productive machine
time, with smart automation that connects sequential
tool production processes and offers connectivity across the
whole factory.
This is Industry 4.0 – factory-wide integration. The technology
considers a factory as a single machine, rather than
separating it into many different elements of design, blank
preparation, grinding, laser marking, washing, packing and
shipment. This is a powerful concept that brings together one
ecosystem and builds it to be as efficient as possible. AIMS,
being a modular solution, could be deployed in stages, allowing
for easy, gradual and smooth transition from traditional
to automated and integrated manufacturing.
An AIMS manufacturing cell will be displayed at
GrindingHub, demonstrating a fully automatic process of
tool manufacturing starting from the pallet with blanks and
finishing with pallets with ground tools. The GrindingHub
demo consists of the following components:
▶ AutoSet – preparation station, it is a main operator
interface. Jobs scheduled for production are loaded down
through the AIMS server to the AutoSet station and are
prepared for production there, pallets are being loaded
with blanks for further automatic process
▶ AutoFetch – AMR (Autonomous Mobile Robot)
responsible for material transfer between processes
replacing operators carrying pallets or individual tools
between machines/processes. The AutoFetch robot will
transfer full pallets with blanks to the respective
grinder, will pick up an individual tool from a grinder
for out-of-process measurement and compensation and
then will pick up a pallet of finished tools and transfer
it to the finished goods area
▶ MX7 Linear grinder equipped with AutoLine advanced
loader (robomate 2 loader with AIMS kit installed),
allowing for accepting pallets presented by the AutoFetch
▶ Zoller Genius with Zoller AutoLine advanced responsible
for out-of-process measurement of individual tools from
no. 2, May 2022
35

machining center
CGX
Automated small batch and
regrinding solution and
insert grinding demonstrations
ANCA understands the requirement to continuously
reduce costs within the production processes which is
a particular challenge in smaller production batches of
complex tools and in regrinding process. To address this
challenge ANCA has developed a flexible solution utilising
RFID technology, the LaserUltra closed loop measurement
and barcode reader interfaced into the iGrind and end-customer’s
ERP system. This system will be demonstrated on
the FX7 Linear platform. The demonstration will highlight
how to set up a tool for regrind using a barcode reader
and a QR code, how to easily make adjustments within
the ANCA software, what inputs are possible in an ERP
system, setting up the RFID to allow mixed diameter automation
and the actual grinding process itself. The FX7
Linear machine will also be fitted with the Pop-Up Steady,
AutoStick, Auto Wheel Qualification and iView.
The stand-alone MX7 Linear with RoboMate loader
will be demonstrating ANCA’s solution for grinding and
auto loading of indexable inserts. The machine and loader
will be installed with workholding, grippers, pallets and
interchange station specifically for the manufacture of
special inserts. Accessories fitted on the machine include
the 4-station Auto Stick, Auto Wheel Qualification and
LaserUltra.
FX Linear
a batch being manufactured. Measurement values are
transferred to the respective grinder and compensation
of grinding parameters is taking place based on
individual customers tolerance settings.
AutoMarkX: Anca’s automatic laser marking station
AutoMarkX is an automatic stand-alone laser marking station
replacing manual and labour-intensive processes. It is
AIMS Ready, which means it can be used as a stand-alone
machine but could be easily integrated to your lights out,
unmanned AIMS manufacturing cell with automatic pallet
transfer using AutoFetch robot.
The AutoMarkX eliminates the need for manual laser
marking which is a repetitive and labour-intensive job which
could be automated and would save money. By avoiding manual
handling, the tool is protected from the risk of chipping.
AutoMarkX accepts up to two full pallets of tools, which
means you can mark a large batch of tools unmanned. Flexible
marking means the message could be etched on one side
of the shank or on opposite sides of the shank or at the end of
the tool. The last option is particularly useful for applications
where a unique tool identification code (e.g. Data Matrix)
needs to be etched on the tool. They are usually etched on the
shank where they are exposed to excessive surface wear, rendering
them unreadable. That’s why it’s best to etch this type
of code at the end of the tool
GCX Linear: gear up for skiving
Driven by the automotive industry’s electrification and the
general rise of e-mobility, the demand for skiving cutters
is increasing 30 % every year. The GCX Linear provides a
complete solution for customers to tap into this rapidly developing
market, including the ability to produce skiving
cutters, shaper cutters and regrinding of hobs. It offers advanced
stand-alone software to design and optimise the
tool, neatly interfaced with the gear tool package inside
ANCA’s renowned ToolRoom software. The machine is
designed for accuracy with features including all axes with
LinX linear motors and an enhanced headstock. GCX
Linear also added a series of technologies: AEMS dressing,
MTC on grinding spindle and dresser spindle, integrated
gear tool measurement and direct compensation – setting
the new standard for producing skiving tools that achieve
the highest DIN AA quality class.
Due to the skiving tool’s novelty, many gear measurement
machines still don’t have the correct mathematical
model for evaluating the quality of the cutter. Leading the
world in solving the quality control issue, ANCA developed
the world-first integrated gear tool measurement system,
which enables the grinding-measuring-compensation
all done in the machine, as the only practical closed-loop
solution.
At GrindingHub, the GCX Linear will demonstrate the
skiving cutter production process assisted with the industry-first
integrated gear tool measurement system.
further information: www.anca.com
36 no. 2, May 2022

machining center
GrindingHub:
“Everything for the perfect gear”
This philosophy is embodied by Reishauer’s
“Circle of competence”. It includes gear grinding machines,
loader systems, process monitoring solutions,
grinding worms, diamond dressing tools and work -
holding devices.
At GrindingHub, Reishauer will focus on the Argus process
monitoring and different tools for the hard fine machining of
gears. A separate room will allow customers to discover the
process monitoring system in depth. Argus makes the grinding
and dressing processes transparent and interpretable.
Four technology tables are available to visitors, showing the
latest developments in grinding wheels, dressers, and clamping
devices.
Reishauer shows a wide variety of clamping solutions, both
hydraulic and mechanical. Hydraulic expansion clamping
systems are advantageous when used with gantry loaders,
which maintain a high positioning accuracy and thus ensure
a long service life of the clamping tools. For ring gears,
mechanical clamping devices are more suitable. Due to the
increased insertion clearance they have a larger expansion
range and allow robot loading.
Reishauer exhibits the full range of diamond dressing tools
for gear grinding, covering all applications from prototype
making to high volume production.
Reishauer will showcase (hall 10, booth D44) a comprehensive
range of grinding tools from its own manufacture,
covering the requirements from grinding individual parts
to mass production and gear honing. Vitrified bonded
threaded grinding wheels for grinding, fine grinding, and
polishing are displayed.
further information: www.reishauer.com
GrindingHub:
Cutting-edge technologies
for high-precision
surface machining
“Solutions for high-precision surface machining” is
the slogan of Supfina’s 132 m 2 booth C10 in hall 10 at
GrindingHub in Stuttgart, Germany. At GrindingHub,
the new hub of international grinding technology,
Supfina will be informing about highlights in superfinishing,
flat finishing, double-disk grinding and
fine grinding technologies, and economical solutions
for automation of production lines and robot-assisted
surface finishing.
Supfina understands its responsibility to provide customers
with comprehensive support and solutions in all fields of
surface finishing: from the development and production of
an optimal surface to the manufacturing of the production
machine and its automation, up to the integration of a machining
process using robotic support.
As a global leader in surface finishing technologies, Supfina
designs and manufactures customized machines and solutions
for machining tasks ranging from small attachments
to complete machining centers with automation.
“We offer our customers complete solutions for the innova -
tive and future-oriented production of highly complex components,”
says Christoph Siegel, managing director of the Black
Forest-based machine builder and solution provider.
With locations in Germany, the USA and China,
Supfina Grieshaber is one of the world’s leading solution
providers and producers of surface finishing equipment.
The company employs more than 200 qualified and
highly specialized employees. The product range includes
machines and equipment for superfinishing, double side
grinding, fine grinding, flat finishing, as well as
automated solutions. Based on decades of experience,
the modern company offers integrated and innovative
systems – including comprehensive services.
further information: www.supfina.com
no. 2, May 2022
37

machining center
Automation and process optimization
Unmanned cylindrical grinding processes for small series
The internationally operating MPS Micro Precision
Systems AG (MPS) consistently uses grinding pro -
cesses for demanding high-precision components in
IT02 tolerance ranges. With a total of seven Studer
grinding machines, the company has a cylindrical
grinding expertise which is second-to-none.
Thanks to automation and process optimization, mediumsized
series are also flexibly produced in unmanned processes
24/7. Future projects and prototypes can be brought to
market more quickly thanks to a flexible production cell.
MPS, with a staff of more than 400 employees, is a “hidden
champion” of a special kind. Back in 1969 RMB (Roulements
Miniatures Bienne SA), from which MPS originated, developed
components for the Apollo Mission. With 250 employees
Biel is the MPS group’s largest site and has more than 140
turning, milling, grinding, polishing and eroding machines.
Manuel Nercide (plant manager): “We have a very varied
range of technology, if you want to reduce it to a common
denominator, then it’s the manufacture and assembly of
complex electromechanical assemblies within the tightest
tolerances for high-precision applications in high-end
segments.”
View of the Studer S21, which is used in the flexible
production cell (Flex Cell); a prototype component
(aluminium pump rotor) is being precision-ground here;
with regard to flexibility: eccentric grinding processes
can be produced without any problem
Consistent investments in grinding machines
Michael Bazzan (production manager): “With seven Studer
grinding machines, we currently have a high grinding
capacity for producing high-precision components. The
grinding machines are matched to our varying lot size
spectrum, which ranges from individual component production
up to 25,000 pieces per year for some references.”
Today MPS high-precision recirculating ball screws are
in demand worldwide and are used in high-performance
microscopes and telescope systems for example,
for precise positioning of lenses
In accordance with the lot size spectrum, three of the
seven Studer machines are currently equipped with an automatic
loading system. The focus in the following is on the
Studer S33 for the production of recirculating ball screws
and a Studer S21 in the area of a flexible production cell
(Flex Cell).
2 µm production tolerance: view of the grinding process
for screw spindles with gothic-arch thread profile
Flexible production cell for prototype manufacture
Didier Noirjean (Flex Cell manager): “The Flex Cell was
recently integrated into cylindrical grinding production as
a self-sufficient production unit, in order to set up grinding
processes for prototypes and new developments without
having to intervene in production. Thanks to this flexible
38 no. 2, May 2022

machining center
production cell our process from development
through to the finished component
is much quicker.
The decisive factor with the Studer
S21 was that it can be changed over
very quickly and it can be flexibly configured
for different components. Eccentric
grinding processes are also
possible with the S21. In this regard
the Studer S21 is perfectly suited to our
requirements.”
While the Flex Cell primarily involves
prototypes, series parts are machined
on the other six Studer machines.
These include recirculating ball
screws with a high-precision design.
Core competency recirculating
ball screws
The smallest recirculating ball screws
have a ball diameter of 0.8mm. All components
are developed and manufactured
in-house by MPS, including the
balls. The larger series of screw spindles
with gothic-arch thread are pro -
duced on a fully automated Studer S33.
The MPS team in front of the Studer grinding machines, from left to right:
Didier Noirjean (Flex Cell manager), Michael Bazzan (production manager),
Julien Grosjean (screw grinding manager), Manuel Nercide (plant manager) –
all MPS and Ulrich Weyermann (regional sales manager Fritz Studer AG)
Ball-type linear drives for
high-precision applications
Manuel Nercide: “We are involved in research and development
with these precision screw spindles. The expertise
developed by MPS Microsystems in the extremely gentle and
precise positioning of lens groups enables the company to
offer powerful alignment systems for optical components
such as zoom and laser beam focusing systems.”
MPS AG: 400 employees – three locations – four units
MPS Micro Precision Systems AG (MPS) is a Swiss
company, which was founded in 1936 with the name
RMB (Roulements Miniatures Bienne SA) and was
renamed as MPS in 2003. The company group has
expertise in the areas of linear ball bearings and miniature
recirculating ball screws as well as competencies in
development, machining and assembly of electromechanical
systems. The electromechanical components
and solutions are characterized by reliability, a high level
of precision and small dimensions. The demanding
markets served by MPS are primarily medical technology,
including orthopedics in particular, as well as the watch
industry, automation, aerospace, science and optics.
MPS Micro Precision Systems AG employs 400 highly
qualified staff and has three locations. The markets are
distributed between four units: MPS Microsystems (this
report), MPS Watch, MPS Décolletage and MPS Precimed.
In addition, MPS can rely on the know-how
of the parent company, the Faulhaber Group, where
electromechanical drives systems are concerned.
Systems designed to customer requirements
MPS Microsystems miniature recirculating ball screws, or
ball-type spindles, are made exclusively of stainless steel and
are positioned with double nuts, which enable fine adjustment
of the axial play. These often customized spindles guarantee
virtually smooth movement thanks to the high precision
of their ground thread. With regard to customized
production: There is a wide range of customized options
available for recirculating ball screws.
Julien Grosjean (screw grinding manager): “Such applications
require the highest precision and positioning accuracy
– 100 % backlash-free. And it is precisely here that our
spindle systems show their strengths. We grind a so-called
gothic-arch thread profile within the tightest tolerance ranges,
so that we can reduce the radial clearance and backlash
to zero.”
Gothic-arch thread: grinding from solid
The gothic-arch thread form is ground directly from the
solid hardened blanks. A macro was developed for these
gothic-arch thread forms together with Studer. The grinding
parameters can be adapted very quickly to the respective
screw spindles with this macro.
Ulrich Weyermann (regional sales manager, Fritz Studer
AG): “The Studer S33 used here is an external cylindrical
grinding machine with a turret wheelhead. Specifically,
the wheelhead used here has two external grinding wheels.
One of the two wheels is used for the thread profiling, while
the second wheel is generally used for external cylindrical
grinding.”
no. 2, May 2022
39

machining center
Handling system for unmanned production
In order to produce the medium-sized series cost-effectively,
the Humard company developed a flexible handling system
for automatic loading and unloading of workpieces in collaboration
with MPS and Studer
Michael Bazzan: “A crucial factor in the design of the handling
system is that it can be quickly adapted to different workpiece
geometries, because our lot sizes are variable.”
Typical thread grinding process
The Studer S33 requires less than a quarter of an hour for the
complete machining of a screw spindle of 8 mm in diameter
and 120 mm in length. The thread is roughed and finished
with the same grinding wheel. The grinding wheel is dressed
repeatedly in the micron range throughout the grinding
process. More than 1,000 screw spindles of this size can thus
be ground with one grinding wheel.
The dressing process with a number of tasks
The grinding wheel dressing process performs an important
function during grinding. On the one hand the dimension
and form of the grinding wheel are calibrated, and
on the other hand the cutting ability of the grinding wheel
is defined.
Thanks to the variable dressing options, the grinding wheels
can be specifically configured to the process with the
diamond dressing roll, also in terms of cutting ability
Julien Grosjean: “In the case of screw spindles we typi -
cally need to dress repeatedly during each production process.
Both a diamond and a dressing roll are used for dressing.
You can define the roughness of the grinding wheel
relatively specifically with the dressing roll, and thus control
the grinding process and the surface quality. We have carried
out many tests in this regard, until finding the ideal dressing
method for the roughing and finishing processes.”
Ulrich Weyermann: “If you consider the complexity of a
grinding process and the dimensions of the machines – keyword
thermal growth – then producing within IT02 tolerances
in unmanned operations is hardly a matter of course.
All seven Studer machines deliver exactly the precision and
process reliability demanded by MPS on a daily basis. 24/7
production with the IT-02 tolerance ranges that we require is
ultimately only possible thanks to the extremely high repeatability
precision of our Studer grinding machines.”
Such electromechanical components are produced and
completely assembled at MPS in Biel; they are used in back
surgery, for high-precision positioning of surgical instruments
Investments reduce production costs
Finally, Manuel Nercide takes a comparative look at the
past: “Seven years ago we made between 2,000 and a maximum
of 5,000 spindles, today we produce 50,000 spindles a
year. We have continually reduced our production costs, not
least thanks to investing in modern grinding machines. Seven
years ago our production was four times as expensive.
From this perspective, investments in modern production
equipment are crucial for ensuring long-term viability. Ultimately,
our production must satisfy the qualitative and quantitative
requirements of our product range. We are perfectly
positioned in the cylindrical grinding segment in this regard,
not least because of our continued investments.”
further information: www.studer.com
40 no. 2, May 2022

machining center
MACH
Vollmer premiered new grinding technology at MACH
Following its world exhibition premiere at EMO
2021, VOLLMER gave its UK exhibition debut to the
new VGrind 360S grinding machine at MACH 2022.
At the Birmingham NEC from 4 th to 8 th of April, VOLLMER
introduced its new VGrind 360S grinding machine for the
complete machining of carbide tools.
Setting the standard in both the machining of solid carbide
cutting tool and saw blades, the new VOLLMER innovations
certainly draw interest from cutting tool manufacturers
at the UK’s showpiece manufacturing event. VOLLMER
is the industry benchmark for the complete machining of rotationally
symmetric solid carbide tools and to demonstrate
this, the impressive new VGrind 360S is the perfect solution
for manufacturing cutting tools for automotive, medical,
aerospace and general subcontract manufacturing industries.
The new 5-axis CNC grinding machine can be used to
machine carbide tools with a diameter up to 25.4 mm and,
depending on the machine kinematics and the equipping of
the grinding wheel packages, it can even be used for tools up
to 150 mm diameter.
What distinguishes this grinding machine is that it has
more precision and power thanks to its innovative linear induction
motor and linear slides on the X-, Y- and Z-axes. By
moving from ballscrews to the linear induction motors and
slides, the VGrind 360S reduces maintenance costs by utilising
contact-free magnets – eliminating wear. Furthermore,
the enhanced kinematics deliver improved precision and
higher surface quality on the cutting tool.
Simple and intuitive operation is central to the VGrind
360S concept and for customers to fully exploit its potential,
VOLLMER has created an ergonomic platform whereby users
can operate the control panel comfortably whilst having full
visibility of the work envelope. Operation via the keyboard
or touchscreen allows for precise machining of the tool and
VGrind 360S
the multi-function handwheel ensures even more flexibility
as it can be freely positioned on the enclosure. This design
allows the setting of a required axis without using the control
panel.
On the VGrind 360S, the groundbreaking vertical doublespindle
concept that has been proven on previous machines,
now features an oriented spindle-stop for the first time.
Known as spindle indexing, this always stops the spindle at
a specific position and the result is a reduction of axial runout
errors and concentricity issues whilst offsetting wear in
the HSK holding system. Another new feature is a heat plate
exchanger to efficiently cool motors and spindles, which in
turn leads to increased thermal stability. This effective cooling
concept has now been optimised to demonstrate absolute
perfection when processing tools to the tightest of tolerances.
The VGrind 360S incorporates VOLLMER’s trusted operating
concept and can be operated unmanned around the
clock thanks to automation features such as a pallet magazine,
free-arm robot or chain magazine. The options for
automation include the HP 160 pallet magazine for up to
900 tools with a double gripper to guarantee fast changeovers,
the HPR 250 free-arm robot for the automatic machining
of tools with various shaft diameters and the HC 4
chain magazine that has space for 39 HSK-63A tools or up
to 158 shank-type tools. This automation also extends to the
8-tool grinding wheel changer that ensures to always supply
the right grinding wheel for the job at hand with no manual
intervention.
further information: www.vollmer-group.com
no. 2, May 2022
41

machining center
Now available worldwide
CUT X series of wire-cutting EDM machine
The AgieCharmilles CUT X wire-cutting EDM
machine series, first announced at EMO Milano 2021, is
now available worldwide, providing extreme accuracy
in a simple and fast way.
With the new high-end CUT X series, GF Machining
Solutions makes use of its over 100 years of experience in
wire-cutting EDM. The new CUT X series in the Pinifarina
design, which includes the CUT X 350 and the CUT X 500
machines, features new technologies that increase operating
precision significantly. The machines are capable of holding
extreme pitch positioning and contouring capabilities for
superb part quality, making them suited for stamping, molding
and micro-machining applications in electronic components
(EC), medical and automotive markets.
One of the features the CUT X series includes is the Uniqua
human/machine interface (HMI), with optimal functionality
and ergonomics in a 19" vertical touchscreen, full keyboard
and mouse. For utmost compatibility, Uniqua supports
As a world premiere, GF Machining Solutions gives the
operator the possibility to work with open or closed guides,
thanks to a quick and simple system of interchangeable
cartridges on the CUT X series
legacy file types from various EDM manufacturers. It also
creates, imports, modifies and executes sequential (ISObased)
and object-oriented (dynamic) programs from previous
versions of VISION and AC CUT, combining their
usabil ity and functionality. With offline and at-the-machine
programming, ISO-based functionality and object-oriented
programming, Uniqua provides a powerful graphic tool with
integrated CAM. It also ensures compatibility with major
CAD/CAM programs.
Apart from the easy-to-use interface Uniqua, machines
in the CUT X series are equipped with the new wire circuit.
Thanks to the unique twin wire plate, the users can choose
between the twin wire technology (the main cut being faster
with bigger wire, while achieving smaller radii with thinner
wire), longer autonomy (thanks to two identical wire spools)
and to reduce contamination (with two wires with identical
diameter but different coating).
The CUT X machine includes two identical, symmetrical
wire circuits for simple, fast roughing and finishing, optimal
cutting speed and accuracy and double wire autonomy
As a world premiere, GF Machining Solutions gives the
operator the possibility to work with open or closed guides,
thanks to a quick and simple system of interchangeable cartridges.
This allows the operator to choose the right guides
depending on the application. The distance from the guide
to the workpiece has been reduced to guarantee the highest
contour accuracy and a more stable process. The new heads,
produced with Additive Manufacturing, optimize the flushing
channels and reduce the distance between the guides and
the parts, which is key to improving the wire straightness and
cleaning conditions during the cutting process. The compact
design of the lower head allows to machine intricate parts.
42 no. 2, May 2022

machining center
Thermal compensation is a new standard feature of the
CUT X series, ensuring ultra-high pitch accuracy
even with high environment temperature change
The new human machine interface (HMI) Uniqua,
here on the CUT P 550 Pro, offers optimal functionality
and ergonomics for every skill level
New X-Technologies in GF Machining Solutions’ database
focus on high accuracy, high surface quality and high-speed
results.
Thermal compensation is a new standard feature of the
CUT X machines, ensuring ultra-high contour accuracy even
with high environment temperature change during long cutting
cycles. The Automatic Wire Threading (AWT) makes it
easy to integrate automation into the process, while the wire
chopper reduces idle time. Thanks to the annealing, job
processing with a correct re-threading is ensured, even under
the most difficult conditions.
Other features will be available on the CUT X series during
the year, like the Intelligent Spark Protection System (ISPS).
Based on the Spark Track technology, the ISPS prevents wire
breakage, detecting variations in the workpiece profile. The
CUT X series is connected to OPC UA, while offering further
options like automatic doors for perfect ergonomics and
full accessibility for the operator, retractable probing and 3D
setup for continous production, and Automatic Slug Management
for a full automated process.
The CUT P Pro series for higher productivity
Before launching the CUT X series, GF Machining Solutions
launched the AgieCharmilles CUT P Pro series of wire-cutting
EDM machines, designed for increased productivity and
ideal for every application with the largest technology database.
The series include the CUT P 350 Pro, the 550 Pro and
the 800 Pro with robust designs and the intuitive interface
Uniqua and automation options for lights-out operation.
With Intelligent Power Generator with Direct Power Supply
(IPG-DPS), also available for the CUT X series, the CUT P
Pro series’ machines deliver surface finishes as smooth as up
to Ra 0.08 μm and heighten accuracy with integrated thermal
regulation that allows to achieve an accuracy of ±2 μm.
Linear scales and rotary encoders form a double measuring
system that protects the X-, Y-, Z-, U- and V-axes. In the case
of collision, the energy absorber system automatically stops
the axes without damage to machine or workpiece. This full
protection applies at machine speeds of up to 3 m/min.
In the QUADRAX® mechanical system of the CUT P Pro
series, the table, work tank and dielectric liquid remain stable,
and the workpiece does not move, accommodating heavy
workpieces. Independent U/V- and X/Y axes with equal
length (X = U travel; Y = V travel), constant, lower mass and
completely independent movements produce large, precise
tapered cuts. In addition, the Rhenocast machine base offers
lower thermal conductivity and a vibration damping system.
Automation solutions for the CUT P Pro series include
Automatic Slug Management (ASM), Automatic Slug Welding
(ASW), and the option of a fixed or retractable Renishaw
mechanical touch probe to measure workpiece planarity and
position on the machine’s worktable. Scalable automation
options from system 3R maintain unattended production,
including a WorkPartner 1+ compact robot with raw materials
that can feed up to two wire-cutting EDM machines for
more than two days without operator intervention.
further information: www.gfms.com
no. 2, May 2022
43

components
Control 2022 – international trade fair for quality assurance
Measuring and positioning cycles synchronise exactly
After Control could only take place virtually last
year, the world’s leading trade fair for quality assurance
opened its doors again in Stuttgart, May 3 – 6,
2022. The motion control experts from Aerotech presented
a whole range of new product innovations in
measuring and testing technology.
In addition to high-precision positioning systems, laser scanning
and measuring technology for quality assurance, trade
visitors were able to see the “small” hexapod HEX150 as well
as test extensively the extended functionalities within the
Automation1 control platform. The SMP multi-axis motion
platform for surface measurement applications was also on
display.
The most precise
hexapod on the market:
the HEX150-140HL, with
travel ranges of up to
55 mm linear and
50 degrees of rotation,
the small movement
artist can move up to
7,5 kg payload almost
completely free
in space
The new Aerotech subsidiary Peak Metrology presented a
high-performance positioning system from the cooperation
with measurement technology specialist Keyence.
“For us as a supplier of high-precision positioning solutions,
Control is by far the most important trade fair event in
the field of quality assurance,” emphasizes Simon Smith, European
director Aerotech. “And since our solutions have always
been widely used in the medical industry, we were also
hoping for a synergy effect from the MedtecLIVE/T4M medical
technology trade fair that took place at the same time.”
Highest precision in the submicrometer range
The HEX150-140HL was for the first time live on show. This
is a miniature hexapod positioning system with six degrees
of freedom (DOF) that enables precise translation in the X,
Y and Z directions as well as rotation around each of these
axes. “The HEX150-140HL offers not only significantly better
minimum incremental motion, but also greater linear
travel than any of its competitors – all in a compact yet rigid
platform,” says Simon Smith. “The combination of small size,
high precision and excellent load capacity also allows for a
much higher degree of flexibility. Users can rely on consistent,
reliable six-DOF movement in every application.”
The HEX150-140HL is ideal for space-constrained applications
with multiple DOFs that require fine positioning resolution,
such as alignment, assembly and interconnection of
photonic components, optical inspection and alignment, optical
wafer probing, aerospace and satellite sensor testing,
and sample alignment in synchrotron and beamline applications.
Other important features are the high load capacity of up
to 7.5 kg with the ability to resist backdriving with force up
to 100 N, the large range of motion for easy integration into
complex applications, and the simple control and programming
with virtual pivot point adjustment. According to
Aerotech, the HEX150 is currently the most precise hexapod
on the market. Fast settling times allow high throughput
with bidirectional repeatability of less than 2 μm, with minimum
incremental motion of less than 20 nm in XYZ and
0.2 μrad in Θx Θy Θz also allow a wide range of applications.
The “HexGen Hexapod” simulation software integrated
in the Automation1 control platform also enables easy programming
and control of the hexapods in any user-defined
coordinate system. The user can visualise and simulate the
available working space in order to perform collision analysis
with his hexapod. In addition there is direct selection of precon
figured models from a stored library of standard designs.
Ideal platform for
surface measurement applications
The production of optical components in laser material processing,
biotechnology, medical technology as well as semiconductor
technology requires highly precise surface measurements
including non-destructive quality assurance.
According to manufacturer Aerotech, the SMP is the optimal
multi-axis motion system for such applications. “Optical
components are used everywhere, for example in medical
technology for prevention, diagnostics and therapy or
for laser processing of materials in additive manufacturing,”
says Simon Smith. “High-precision optics require high-precision
measurements of spherical, aspherical and cylindrical
shapes, in the nanometer range. A prerequisite for this is flexible
2D and 3D contouring.” The measuring device benefits
from the performance of the Aerotech controllers with their
advanced motion control and position synchronised output
(PSO), which enables very smooth movements even at the
lowest speeds.
A generic high-speed electrical interface between motion
and sensor control enables axis repeatability in the lower nano
meter range by synchronising measurement and position
44 no. 2, May 2022

components
data in real time. As a result, incremental motion at the
nanometer level is extremely minimal, supporting the generation
of accurate scan or point-to-point motion profiles. As
shown in field tests and practical applications, the processing
time for surface measurements is reduced by up to 40 % due
to the excellent positioning properties. Another unmistakable
plus point is the space saving: an SMP requires up to
60 % less floor space than cartesian measuring systems.
Application example of an
integrated surface metrology
positioning system from
Peak Metrology with a
Keyence VHX series
digital microscope
One platform for all applications
Attendees of the show could also see the latest release of Automation1,
Aerotech’s most advanced Motion Control Platform.
Replacing Aerotech’s legacy Control platforms (A3200,
Ensemble and Soloist), Automation1’s suite of Drive-based
and PC-based controllers bring new, more powerful features
into one common easy to learn and use architecture.
Building on the previous releases, version 2.2 brings new
features to the platform including the much anticipated
machine Apps HMI development tool. Replacing the previous
CNC operator interface, this new and fully customisable
tool promises to revolutionise user facing interfaces for motion
systems. Automation1 is now also EtherCAT compatible,
which brings new opportunities for interfacing to PLC based
systems, and widens the options when considering the needs
of high precision motion processes when embedded within a
traditional lower precision machine.
Other key developments include:
◉ improved interfacing to Automation1 with the addition
of Labview VI’s and a Python API.
◉ the dynamic controls toolbox (a popular feature in
A3200) which brings together Aerotech’s Harmonic Cancellation,
Command shaping and Cross-axis feedforward
features, newly improved by our world leading experts.
◉ closed-loop stepper motor control
◉ facility wide backup and restore capability by using
Aerotech’s enhanced API functionality.
“These latest enhancements mean that Automation1 is
truly a complete machine control system and much more
than a mere ‘motion control system’”, says Simon Smith,
describing the main advantage over comparable solutions.
Aerotech presents its new release of the user-friendly
control platform “Automation1” at the trade fair
Aerotech subsidiary Peak Metrology
also at the exhibition stand
Control is the first trade show in Europe for Aerotech to colocate
with its new subsidiary, Peak Metrology. Headed by
RJ Hardt, a long-time Aerotech engineer, Peak Metrology
draws on Aerotech’s extensive positioning systems expertise,
but focuses exclusively on helping industrial customers with
surface metrology solutions through to complete integration.
The demosystem on the Control (LF-D) shows how large
format stages extend the visible area available to a VHX digital
microscope from Keyence. This enables larger parts to be
inspected and measured, compared to the smaller standard
stage offerings. Furthermore the resolution of the microscope
is retained, and the machine as a whole is capable of taking
nanoscale images over large surface areas. Additionally,
added features such as motorized tilt stages, programmable
image capture and autofocus routines, and fiducial based
part alignment are available.
These machines are commonly used in the electronics and
semiconductor markets to image and measure small features
over large parts. Large circuit boards and panels as well
as semiconductor wafers are ideal products to inspect with
these large format positioning systems. Material science,
dimensional measurement, and surface characterization of
other precision manufactured components are also applications
where these machines excel.
Peak Metrology offers a wide range of products for surface
metrology applications, including turnkey machines. Surface
analysis is often integrated directly into the production chain
as a quality assurance process, for example in semicon ductor
production, wafer inspection or the manufacture of flat
panels. Here the quality is assessed after almost every process
step, for which a fully automated in-process inspection
with object feeding, measurement and subsequent further
processing is usually triggered. It is essential that measuring
and positioning cycles are precisely synchronised. Users benefit,
among other things, from high-performance linear and
ro tary tables as well as controls with position-synchronous
triggering of the sensor.
further information: www.aerotech.com
no. 2, May 2022
45

components
Strategic partnership with
Japanese tool grinding machine manufacturer
The Japanese Seiwa Corporation has recently
started using the WGT 400 gear inspection machine by
Liebherr to measure the tools that are used for its
customers. The manufacturer of machine tools for the
gear industry has confidence in the measuring instrument’s
excellent precision. Liebherr is now offering
tool grinding machines made by SEIWA, in order to
expand the product portfolio for their customers.
President Toshihiko Tatsu
puts the WGT 400 into operation
In south-west
Japan, situated
by the Sea of
Japan and
Lake Shinji,
one of the
country’s
largest inland
lakes, lies the
picturesque
coastal town
of Izumo. It
is famous,
among other
things, for one
of the oldest
and most
significant
Shinto shrines
in Japan:
Izumo Taisha.
Not far from
there is the headquarters of Seiwa Corporation, a leading
manufacturer of machine tools for gear manufacturing in Japan.
For Toshihiko Tatsu, the president and majority shareholder
of Seiwa since 1994, this location has a special significance:
“In Japanese mythology, Izumo is the country’s birthplace.
The art of forging and steel processing also have a long
tradition here, which continues to inspire us as a mechanical
engineering company.”
International sales partnership
Seiwa, which celebrated its 100 th anniversary in 2020, is
proud of its tradition as a customer-oriented solution pro -
vider: “With just under 100 employees, we supply leading
companies of the Asian automotive industry and gear manufacturers
worldwide”, president Tatsu explains. “We place
great significance on innovation and technological progress
and have been involved in research cooperation with universities
and research centers for a long time.”
Liebherr has opened its own sales office in Japan in 2015.
The contact between the two companies was brought about
by Kiyoshi Iguchi, director sales & service at Liebherr in
Japan. Ultimately, Toshihiko Tatsu was won over by
Seiwa Corporation
company size: 100 employees
founded: 1920
headquarters: Izumo, Japan
locations: Izumo, Osaka, Tokyo
website: www.segtec.jp/english/
Liebherr’s presence as a complete provider of tools, machines
and technology. This gives him confidence in the quality
and precision of Liebherr’s measuring technology. Peter
Wiedemann, managing director of Liebherr-Verzahntechnik
GmbH, expects new impulses for international business
to result from the sales partnership: “For us the strategic
partnership with Seiwa is a springboard into new markets,
which we are happy to use.”
The WGT 400 – universal and accurate
The company is well-known in the Asian market for the high
quality of its products. Since March 2021, quality control of
the tools used by Seiwa has been carried out on the WGT 400
gear inspection machine by Liebherr. It is also there available
for tests and customer presentations.
The WGT 400 is a universal gear inspection machine which
is suitable both for gear and for tool measurement and which
provides a high-quality alternative to other common in spection
machines. Lapped granite guides, air bearings, precision
rotary tables and Renishaw probe systems ensure the
mechanical precision of the machine. On the WGT, any
type of gears, shaft geometries, gear cutting tools and other
rotation-symmetrical workpieces can be measured – individually
configured by Liebherr according to user requirements.
Each model fulfills the quality standard of group 1
according to VDI/VDE 2612/2613 and measures gears from a
module of > 0.12.
The machines are installed and commissioned on site by
Liebherr service specialists. In addition, training is provided
which is adapted to the specific customer, as well as service
support packages. The WGT is equipped with an extensive
software package, which includes not only gear and tool
measurement but also integrated chamfer measurement. The
measuring results can be evaluated according to the different
country-specific norms – for example, according to JIS in
Japan or AGMA in the USA.
Customer benefit for both sides
Toshihiko Tatsu expects, in particular, that the Liebherr gear
inspection device will optimize the precision and quality of
the measurement of tools used to machine very small parts:
“We are currently putting a lot of work into machines for the
production of internal gears and gears with very small
46 no. 2, May 2022

components
modules. We are also hoping for an increase in efficiency due
to the WGT 400’s high measuring speed. The supply of data
in real time is a real advantage: since our largest customer,
Honda, also uses a WGT 400, this will make exchange of data
a lot easier.”
Liebherr, in turn, is expanding its product portfolio with
tool grinding machines: the grinding machines from Seiwa’s
FABRIS product line sharpens the hobs for the machining of
straight and helical gears. Until now, Seiwa machines have
been well-known in the Asian market, where their stability
and precision are valued by manufacturers and users.
Liebherr customers will now also benefit from this: “We are
taking this step because we are convinced of the quality of
Seiwa’s machines”, says Kiyoshi Iguchi.
Two companies, one philosophy
Iguchi also has confidence in the company: “Seiwa is an
agile, pragmatic company with a hands-on mentality, close
customer contact and lots of experience – small but fine, and
well connected in the Japanese gear world.” Both Liebherr
and Seiwa view themselves as innovative solution pro viders
focusing on the customer and their individual requirements.
When asked what he particularly values about Liebherr,
Toshihiko Tatsu says: “The foreman system in Germany stands
for the craftsmanship which is greatly valued in Japan. I am
impressed by the quality awareness of the Liebherr technicians
and always have the feeling that one can learn a lot
from them. This is probably the factor that makes Liebherr a
top brand.” Both companies are convinced that the consensus
between the companies’ philosophies is a good basis for
a partnership and that their customers will benefit from the
expanded product portfolio and technological expertise.
From left to right: Yoshio Itoh (president, L+M Corporation),
Toshihiko Tatsu (president, Seiwa Corporation),
Kana Nakayama (sales, Liebherr Japan) and Kiyoshi Iguchi
(branch director, Liebherr Japan) during a visit
to the Shinto shrine Izumo Taisha
further information: www.liebherr.com
Celebrating 50 years of excellence
in cutting tool manufacture
US cutting tool manufacturer Tool Alliance celebrated
50 years of highly successful business in March
2022. During this time, the company has grown
steadily and in the process has built an enviable reputation
for the quality and durability of its solid carbide
and indexable carbide cutting tools.
Tool Alliance makes extensive use of CNC grinding
machines from various manufacturers, but
has chosen to standardise the
machines’ control
systems on
Tool Alliance’s
innovative Ultra-Tool
Series 365 solid carbide end mills
feature a patented variable-helix geometry and are
produced on high performance 5-axis CNC grinding machines
NUM’s Flexium CNC platform and NUMROTO software,
primarily for reasons of performance and production efficiency.
Tool Alliance is one of the largest licensees of
NUMROTO in the United States.
Founded in 1972 and still held privately, Tool Alliance operates
a number of company-owned factories – its principal
manufacturing facilities are located in Huntington Beach,
California, and in Fort Myers, Florida. The company’s cutting
tool products and services include such renowned brand
names as Ultra-Tool, RoundTool Laboratories, Tungsten Tool-
Works, Routco and Mil-Tec. All five brands are sold worldwide,
and are supported by shared research, design, engineering,
manufacturing, marketing and sales facilities.
The owner and president of Tool Alliance, Dave Povich,
is no stranger to the cutting tool industry. A past-president
of the United States Cutting Tool Institute (USCTI), he has
worked for the company since 1987. According to Povich,
“NUM is our CNC technology partner, which creates a
no. 2, May 2022
47

components
Tool Alliance makes extensive use of CNC grinding machines
at its manufacturing facilities
win-win situation for both companies. We benefit from having
a direct technical input to NUMROTO software development,
while NUM gains valuable feedback on the design and
production of the very latest cutting tools.”
Tool Alliance’s innovative Ultra-Tool series 365 high performance
end mills are a case in point. Designed specifically
for the machining of exotic materials, these solid carbide
tools feature a patented variable-helix geometry combined
with a proprietary edge preparation/PVD coating combination
that allows for world-class dynamic milling of tool paths,
including most slotting cut applications. The tools are produced
on high performance 5-axis CNC grinding machines
using NUMROTO, employing monitored tool run-out, realtime
deviation compensation and the latest diamond abrasive
technology utilising advanced wheel truing equipment.
Tool Alliance has chosen to standardise the control systems
of all its CNC grinding machines on NUM’s
Flexium CNC platform and NUMROTO software
From left to right: Mark Wortsman (technical director of Tool
Alliance), Dave Povich (owner and president of Tool Alliance),
Patrick Schmid (NUMROTO project manager),
Steven Schilling (general manager of NUM Corporation)
Mark Wortsman, Tool Alliance’s technical director, says
that collaborating with NUM has multiple advantages. “The
NUMROTO team is very supportive and always amenable
to suggestions, which makes life a lot easier for us, as well as
our customers. For example, we recently suggested adding
categories for collets, and some new features for wheel probing
and automatic 3D collision checking; these have all been
implemented in the latest version of NUMROTO software.”
“We consider the 3D-simulation capabilities of NUMROTO
to be the most accurate in the tool grinding world; they help
us to optimise tool programming by preventing any grinding
errors that might otherwise be caused by imperfect wheel
measurement or incorrect machine alignment.”
Wortsman also points out that NUM’s software helps simplify
shop floor management. “Over the years we have built
an extensive library of tools that we have produced with
NUMROTO. The NUMROTO team has done a superb job
of incorporating the library in a centralised industry-standard
SQL database which can be accessed from any of our
machines or programming stations. The database can store
tens of thousands of tool programs which can be accessed by
several hundred users – at the same time if needed.”
“It is much easier to backup a single centralised database file
instead of having to backup files from the computers on each
machine – we perform automated backups several times a day,
just to ensure productivity continuity in the event of a machine
breakdown. Software updates are also handled very efficiently.
As soon as a key NUMROTO update is available, we
can bring all our machines, regardless of make or model, up
to the same software revision level.” Many of Tool Alliance’s
CNC grinding machines are equipped with automatic loading
systems to facilitate overnight production – in fact, some
run for two days in a row without interruption and without
the need for any manual compensation. To keep the
tool dimensions within tolerance, the company relies on the
NUMROTO software’s ‘measurement in process’ feature,
which automatically measures tools after grinding and applies
appropriate compensation. A number of projects undertaken
by Tool Alliance have warranted installing early generation
CNC machines and then retrofitting them with NUM’s
latest motors, drives and CNC systems. Steven Schilling, general
manager of NUM Corporation, “Again, we were able to
help. Our CNC team in Chicago provided local support, and
we were able to improve the performance of the machines’
spindles and axes. It has been, and continues to be, a pleasure
to be a partner to the success of Tool Alliance.”
further information: www.num.com // www.toolalliance.com
48 no. 2, May 2022

components
Sealing technology increases plant and process reliability
The service life of driven tools has a significant
influence on the overall equipment effectiveness of
machines. Sophisticated sealing technologies play a
key role. The influence on process reliability of sealing
technologies used in driven mold systems is
often underestimated. When tool holders were still
predominantly externally cooled, the problem was
manageable. With the advancement of cutting tool
technology, more and more reliance is being placed
on internal cooling technology. For the technology of
driven tool systems, this means that the cooling emulsion
must reach the internal cooling channels through
a rotary union.
If one considers that machine tools run in concatenation or
that there are machines that operate with three tool carriers,
it becomes clear: the process reliability of tool systems plays
an important role. The more driven tools are operated in a
machining unit, the greater the risk that one of them will fail.
As a result, the entire manufacturing cell comes to a standstill.
Sealing units are often the Achilles’ heel of the tool
systems.
Sealing technology at EWS:
on the way to a suitable solution
The topic of sealing technologies is decades old. However,
today’s requirements pose a whole new challenge to them.
The influencing factor of sealing technology is reaching a
significant importance. This is also clearly reflected in the
development sprints of EWS Tool Technologies.
“With the introduction of EWS Matrix Seal technology we
got a solution that guaranteed 25 bar for the seals over the
entire speed range of our machines,” says Lorenzo La Rosa,
team leader application engineering at DMG MORI Management
GmbH. If more pressure was needed additional rotary
unions were available. With good emulsion quality these
could provide pressure resistance of up to 70 bar, which
was necessary for the requirement profile of the high-tech
machines.
EWS HPC-Line
The quality standard of the machines is very high, as they
often work at the limits of what is technically possible – and
usually around the clock. However, one problem was always
present, explains Lorenzo La Rosa: “Whether EWS Matrix
Seal or other sealing technologies, they all require the oil portion
of the emulsion to lubricate the sealing lip or surfaces.”
Even a dry-running run-in process thus runs the risk of causing
initial damage to the seal set. Using a dry-running technology
instead is not a sensible alternative, as it is up to five
times more expensive. The challenge: on the one hand, the
new rotary feedthrough technology was to reliably control
pressures of up to 70 bar in a straight mold unit without an
offset output spindle. On the other hand, it had to be capable
of unrestricted dry running and be compact – and of course
economical. “It was the interaction of the various influencing
variables that first had to be analyzed. Frictional forces,
hydrostatics, component geometries and manufacturing
technologies had to be optimized and coordinated,” says
Michael Wiesenberg, project manager for sealing technology
at EWS.
EWS HPC-Line: novelty on the market
for maximum process reliability
The result was the EWS HPC-Line (High Pressure Ceramics).
At the heart of the ceramic-based cartridge sealing unit,
which consists of several parts, are two coaxially mounted
ring elements that float in the interior. When the tool system
is used, the sealing elements contact the tangential flanks of
the carrier system within milliseconds. During this process,
the sealing elements stand still and seal against the rotating
carrier system in frictional contact. Polished running surfaces
and a geometrically optimized pressure chamber reduce the
frictional force* (Fr = μ x Fp) to a minimum, thus creating the
prerequisite for transmitting up to 100 bar of pressure – at
speeds of up to 12,000 rpm. The minimum leakage that occurs
during the seal closing process is dissipated pressure-free on
the machine side via an expansion chamber. “Maximum process
reliability in our technologies is one of the basic requirements
for us, which we can use a bit more effectively with the
EWS HPC-Line,” says La Rosa. Nowadays, machine tools offer
outstanding quality and great kinematic as well as dynamic
possibilities. It is now important to recognize and optimize
other influencing variables in order to increase the productivity
level of the machine tools and ensure process reliability.
“It is precisely this knowledge that drives our development
thinking and our product strategy,” says Hüseyin Sivaz, sales
manager at EWS. “Our sealing technology as well as our new
gearboxes with polygonal power transmission in the area of
angle heads are guarantors for an extended service life.” Also
not to be neglected, he adds, is the efficient remanufacturing
drive provided by the EWS Varia quick-change system, true
to the motto “Pit stops are where you win races.”
* Fr = frictional force, μ = friction factor, Fp = compressive force
further information: www.ews-tools.de
no. 2, May 2022
49

components
GrindingHub:
An eye for details
For 75 years, the Swiss company ISOMA GmbH
has specialized in high-precision optical measurement
technology and has made itself a name with a focus on
technology, innovation, ergonomics, and highest quality.
At GrindingHub, which will take place for the first
time in Stuttgart from May 17 th to 20 th , 2022, ISOMA
will be exhibiting innovative Swiss made microscopes.
“The ISIscope® microscope for the measurement of precision
parts and the MINIscope for the EWAG WS11 universal
grind ing machine will be on display for the first time in Germany,”
reports ISOMA managing director Thomas Reber.
Centering microscopes and a LIVEscope will be show cased
also at the joint booth with Tschudin AG (hall 9, booth D50).
ISIscope ® : compact and innovative
The new, compact microscope for the measurement of precision
parts ISIscope® impresses with a 3-stage zoom and
optics without moving elements. A granite base ensures maximum
stability and accuracy. A high-resolution, integrated
screen with flexible connection and ergonomic use, the complete
integration of lighting and zoom as well as the simplest
operation makes measuring and monitoring precision parts
in the production particularly efficient. The latest software is
always available. The microscope can also be operated easily
and intuitively with oily fingers, gloves or ESD protective
equipment. The ISIscope® received the IF Design Award 2021
for its design and ergonomics.
Alain Geiser, head of research and development at ISOMA,
explains: “Our innovative IsomAPP opens up new possibilities
in measurement technology: just like on a smartphone,
specific measurement tasks or functions such as DXF glass
plan comparisons, the automatic measurement of any number
of parts, the automatic edge detection for particularly fast
measurements or the comparison of thread profiles are possible
directly on the microscope screen.” The user-friendly app
speeds up the process, saves costs and reduces the possibility
of human error. A PC is not required as the stand-alone
microscope has interfaces for data exchange.
MINIscope for EWAG WS11
In addition to the ISIscope®, the MINIscope is also celebrating
its German premiere. The digital microscope with highresolution
image ensures perfect recognition of all details
and was specially developed for 100 % compatibility with the
EWAG WS11 universal grinding machine. “The compact, robust
design made of aluminum, the simple integration, the live
transmission to a high-resolution screen – the MINIscope
sets new standards in terms of efficiency and precision,” emphasizes
Thomas Reber. The improved ergonomics ensure
less downtimes and better working conditions for employees.
At GrindingHub, the microscope can be seen in combination
with an EWAG WS11.
The ISIscope® from ISOMA with a high-resolution,
integrated screen makes measuring and
observing precision parts easy and efficient
ISOMA microscopes, hardness testers and visualization
systems are used for production and quality control in the
watchmaking, medical, electronics, automotive and aeronautics
industries. “Our high-precision optical measuring devices
guarantee quality, robustness, reliability, and ease of use. All
core components are developed and produced directly at our
company headquarters in Switzerland – from the mechanics
and electronics to the software and the optical elements,”
says R&D manager Alain Geiser. Managing director Thomas
Reber adds: “We use the latest technologies and are con -
stantly looking for improvements and innovations. This is
what ISOMA has been about for 75 years, and we will continue
to follow this path into the future.”
further information: www.isoma.ch
50 no. 2, May 2022

impressum
ISSN 2628-5444
publisher
Benno Keller
tel: + 49 (0)911 - 2018-200
fax: + 49 (0)911 - 2018-100
keller@harnisch.com
editor-in-chief
Eric Schäfer
tel: +49 (0)911 - 504 98 82
fax: +49 (0)911 - 506 38 32
eric.schaefer@harnisch.com
managing editor
Christiane Ebner
tel: +49 (0)911 - 2018-260
fax: +49 (0)911 - 2018-100
ebner@harnisch.com
editor
Tanja Pinke
tel: +49 (0)911 - 2018-130
fax: +49 (0)911 - 2018-100
pinke@harnisch.com
Publishing company
Dr. Harnisch Publications
management board
Dr. Claus-Jörg Harnisch
Benno Keller
Eschenstrasse 25
90441 Nuremberg
Germany
tel: +49 (0)911 - 2018-0
fax: +49 (0)911 - 2018-100
hpt@harnisch.com
www.harnisch.com
www.hptooling-mag.com
advertising Germany, Austria, Switzerland
Thomas Mlynarik
tel: +49 (0)911 - 2018-165
tel: +49 (0)9127 - 902 346
mobile: +49 (0)151 - 548 181 81
fax: +49 (0)911 - 2018-100
mlynarik@harnisch.com
advertising Europe
Britta Steinberg
tel: +49 (0)2309 - 574 47 40
mobile: +49 (0)176 - 478 601 38
fax: +49 (0)911 - 2018-100
steinberg@harnisch.com
advertising, North American editor
USA, Canada
Bill Kaprelian
tel: +1 (0)574 - 292-19 25
kaprep@harnisch.com
advertising China, Hong Kong, Taiwan
Mike Hay
tel: +852 (0)9096 - 8895
mchhay@ringier.com.hk
advertising Taiwan
Sydney Lai
tel: +886 (0)4 - 232 973 18
sydneylai@ringier.com.hk
Four issues per year
printed by
Schleunungdruck GmbH
Eltertstrasse 27
97828 Marktheidenfeld, Germany
VAT DE 133 510 873
The articles contained in this magazine,
including the illustrations, are subject
to copyright law. Any use without the
consent of the publisher is not permitted
and will be prosecuted. This applies to
every conceivable form of reproduction.
Copies and reprints can be ordered on
request. Articles which are identified by
name or which are to be assigned to an author
by an abbreviation do not necessarily reflect
the opinion of the editorial staff.
Unsolicited manuscripts cannot be returned.
If a manuscript is accepted by the editorial
staff, publishing and copyright law as well
as all rights for publication and distribution
are transferred to the publisher. The
publisher
accepts no liability with regard to the facts
set out in these articles.
copyright © 2022 Dr. Harnisch Publications
editorial
Aerotech, Inc. ...................... 44
ANCA Pty Ltd. .................. 26, 34
BENZ GmbH Werkzeugsysteme .......22
CemeCon AG .......................31
CERATIZIT Deutschland GmbH .......6
CERATIZIT S.A. ................... 20
DMG MORI Aktiengeseelschaft .......34
EMUGE-Werk GmbH & Co. KG .......19
EWS Weigele GmbH & Co. KG ........49
Fritz Studer AG .....................38
GF Machining Solutions ............ 42
GrindingHub .......................28
Haas Schleifmaschinen .............. 24
HANZA AB ........................22
Hartmetall-Werkzeugfabrik
Paul Horn GmbH ..................10
Hyperion Materials &
Technologies, Inc. .................11
ISOMA GmbH ......................50
advertising index
company finder
ISTMA – International Special Tooling
& Machining Association ...........23
Kern Microtechnik GmbH ............21
KYOCERA Fineceramics Ltd. ..........9
Lach Diamant
Jakob Lach GmbH & Co. KG .........14
Leuco Ledermann GmbH & Co. KG ....16
Liebherr-Verzahntechnik GmbH ..... 46
MAPAL Fabrik für
Präzisionswerkzeuge Dr. Kress KG ...12
NUM AG ...........................47
Platinum Tooling Technologies, Inc. ...17
Reishauer AG .......................37
Schunk GmbH & Co. KG .............16
Supfina Grieshaber GmbH & Co. KG ...37
TAITRA ...........................23
Tschudin AG ........................32
UNITED GRINDING Group .........18
VOLLMER WERKE
Maschinenfabrik GmbH ........ 33, 41
ANCA Europe GmbH ...................................................page 17
Boehlerit GmbH & Co. KG ...............................................page 3
CERATIZIT Deutschland GmbH ......................................front cover
Fritz Studer AG ...............................................inside front cover
Günther Effgen GmbH ..................................................page 21
Lach Diamant Jakob Lach GmbH & Co. KG ............................. back cover
Liebherr-Verzahntechnik GmbH .........................................page 11
Reishauer AG ..........................................................page 19
no. 2, May 2022
51

A must for every
Tool Grinding Service
The Pioneer invites you
Universal – Dia – Sharpening
for all PCD Tool Applications
See you on GrindingHub Stuttgart
17-20 May · Hall 7 Stand C41
® ®
Video
Machine Demonstration
since 100 years 1922 – 2022
www.lach-diamant.de · office@lach-diamant.de