hpt 2022 #3
■ Seeing mobility change as an opportunity ■ Stable trend towards automation in the metal cutting industry ■ Tradition. Passion. Innovation: How it all began ■ Automated disassembly of battery systems
■ Seeing mobility change as an opportunity
■ Stable trend towards automation in the metal cutting industry
■ Tradition. Passion. Innovation: How it all began
■ Automated disassembly of battery systems
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ISSN 2628-5444<br />
high precision tooling<br />
Machine Tools, PCD, PVD, CVD, CBN, Hard Metal <strong>2022</strong> – 3<br />
■ Seeing mobility change as an opportunity ■ Stable trend towards automation in the metal cutting industry ■<br />
■ Tradition. Passion. Innovation: How it all began ■ Automated disassembly of battery systems ■
Tradition. Passion.Innovation.<br />
For more information visit<br />
www.lach-diamant.de<br />
office@lach-diamant.de<br />
100 years of innovation since 1922<br />
AMB Stuttgart - Hall 3 · Stand D12<br />
®
ISSN 2628-5444<br />
editorial<br />
Adding highlights…<br />
Eric Schäfer<br />
editor-in-chief<br />
…was reserved for the old<br />
masters of the fine arts in earlier<br />
times, who gave their paintings<br />
a dab-like light effect with a<br />
brushstroke. In their own way<br />
the heroes of our cover story<br />
are also artists who worked<br />
brilliantly together. And just as<br />
in art the interplay of highlights,<br />
reflections and shadows results<br />
in a realistic-looking painting, the collaboration between the<br />
right tool with a perfect cutting edge, an excellent machine<br />
and experienced specialists results in perfect surface finishes<br />
with a mirror finish. Machining centers and precision<br />
tools will also get their glamorous appearances at AMB,<br />
International Exhibition for Metalworking in Stuttgart.<br />
First product announcements can already be found in<br />
this issue of hp tooling.<br />
The trend towards automation in the machining industry<br />
continues and now extends through the entire production<br />
chain. To achieve this all links in the chain must be<br />
interlinked. The article on page 48 shows what an<br />
efficient automation concept for machining<br />
operations can look like.<br />
Speaking of efficiency. The recycling of battery systems<br />
will play an important role for sustainable electromobility<br />
in the future, but requires a high degree of automation<br />
in the dismantling process for ecological efficiency.<br />
Authors Thomas Götz and Andreas Gebhardt from the<br />
Fraunhofer Institute for Manufacturing Engineering<br />
and Automation IPA describe how industrial disassembly<br />
of battery modules and e-motors can be carried out.<br />
Eric Schäfer<br />
editor-in-chief<br />
high precision tooling<br />
Machine Tools, PCD, PVD, CVD, CBN, Hard Metal <strong>2022</strong> – 3<br />
Come and see for yourself:<br />
www.harnisch.com<br />
■ Seeing mobility change as an opportunity ■ Stable trend towards automation in the metal cutting industry ■<br />
■ Tradition. Passion. Innovation: How it a l began ■ Automated disassembly of battery systems ■<br />
Perfectly positioned.<br />
The international specialist magazines from Dr. Harnisch Publications<br />
You can now explore our newly designed website, with a<br />
clear focus on responsive design and easily usable applications.<br />
Alongside the free-to-use digital magazine editions, you will<br />
find bonus news coverage, events, subscription and<br />
general information on all our magazines. Take a look at<br />
www.harnisch.com for all relevant content.<br />
Our publications include:<br />
- Technology & Marketing -<br />
no. 3, August <strong>2022</strong><br />
3
table of contents<br />
cover story<br />
High quality diamonds for a brilliant result<br />
Dazzling teamwork between SIT, Horn and Mazak 6<br />
materials & tools<br />
Solid PCD endmills – a new opportunity for increased productivity for those ready to strike 10<br />
The right tool for high-quality tapping 12<br />
Flexible changing system reduces inventory and changeover time significantly 14<br />
Double feed with the same axial force 16<br />
Successful shift work 17<br />
LACH DIAMANT looks back on 100 years – 13 th part<br />
Forty years of spark erosion for efficient PCD machining – utilizing sparks over grinding 18<br />
processes<br />
High precision HSC machining in mold making for medical technology 26<br />
Seeing mobility change as an opportunity 28<br />
machining center<br />
Welcome to the Machine. Farewell to the past… 30<br />
Como Industries quintuples pin gauge output with the TSCHUDIN CUBE 350 33<br />
Planetary lapping machine for PCD and CVD 34<br />
The new productive STUDER machine S36 35<br />
Big cost savings into aerospace production 36<br />
Highest precision with two options 37<br />
components<br />
Automated disassembly of battery systems<br />
Thomas Götz and Andreas Gebhardt, IPA 38<br />
Analyzing and optimizing cleaning processes 44<br />
Reliable cable guiding on industrial robots 47<br />
Efficient automation with robotics, software and storage system 48<br />
news & facts 19<br />
fairs 24, 50<br />
impressum & company finder 51<br />
4 no. 3, August <strong>2022</strong>
ARGUS-Eyed Focus on<br />
the Grinding Process<br />
Reishauer‘s ARGUS process and component monitoring offers<br />
insight into the grinding and dressing process previously thought<br />
impossible. Among others, ARGUS monitors grinding processes,<br />
optimizes them with data analysis, recognizes maintance issues<br />
in advance, reduces down-time to a minimum:<br />
• Grinding and dressing monitoring<br />
• Collision monitoring<br />
• Monitoring of machine components<br />
• Web-based process overview<br />
• Data analysis<br />
• Process optimization<br />
• Potential zero-defect manufacturing<br />
Come and visit us at the<br />
Hall 5/Booth B51<br />
Reishauer AG | info@reishauer.com | reishauer.com
cover story<br />
High quality diamonds for a brilliant result<br />
Dazzling teamwork between SIT, Horn and Mazak<br />
(source: Horn/Sauermann)<br />
“We branched out into the sectors that others had<br />
avoided”, says company founder Walter Schumacher.<br />
Together with his son, Stefan, he runs the company<br />
Walter Schumacher Impuls Technik GmbH, (SIT).<br />
The company specialises in the development and production<br />
of special valves and stand-alone valve so lutions,<br />
which are used in numerous industries.<br />
The product range includes valves for all types of media,<br />
ranging from high-vacuum valves to high-pressure valves<br />
rated up to 800 bar. One of these special solutions made from<br />
aluminium consists of several helium valves, various sensors,<br />
pressure relief valves and throttles, which control and<br />
regulate various pressures. The emphasis is on the surface<br />
quality of the mating surfaces, which ensures functionality<br />
in high-technology analysis. SIT achieves a surface quality<br />
of Ra 0.012 µm (4.724409e-7") using a diamond tool from<br />
Paul Horn GmbH and by having invested in a new turning/<br />
milling center from the machine manufacturer Mazak.<br />
“Our surface finish specification at the start of the project<br />
was Ra 0.02 µm (7.87402e-7")”, says Stefan Schumacher.<br />
The surface quality of the valve block plays a crucial role, as it<br />
acts as a sealing surface in the valve assemblies. “Sealing hydraulic<br />
valves with oil pressures of around 450 bar is technically<br />
relatively simple to implement. With valves for controlling<br />
the flow of helium or other gases, that have to tolerate<br />
pressures of up to 800 bar, this is technically a very difficult<br />
challenge, which not many people want to take on”, explains<br />
Walter Schumacher. Even with technical perfection, it is not<br />
possible to produce a perfect sealing surface. The leakage<br />
value is 1 x 10-7. For this reason, the almost perfect, brilliantfinish<br />
surface of the valve block plays a key role.<br />
Complete valve block machining<br />
Before making the move, SIT relied on a specially developed<br />
polishing process to produce the valve block after machining.<br />
However, the time and personnel required for reworking<br />
meant that optimisation was required. SIT lacked the<br />
right machinery for this, however. After moving to the newly<br />
built company headquarters, investments in a new turning/<br />
milling center made it to the planning stage, but the machine<br />
manufacturer was yet to be selected. “We approached a few potential<br />
suppliers with our requirements. Mazak immediately<br />
expressed a high level of interest and proposed a complete<br />
valve block machining solution”, says Stefan Schumacher.<br />
6 no. 3, August <strong>2022</strong>
cover story<br />
A successful cooperation since 20 years:<br />
Stefan Schumacher (SIT) talks to Paul Hauser and<br />
product manager Jürgen Schmid (both at Horn)<br />
(source: Horn/Sauermann)<br />
The solid workholding attachment developed by Mazak<br />
(source: Horn/Sauermann)<br />
The company opted for the INTEGREX i-200ST turning/<br />
milling center. The INTEGREX is designed for rigidity and<br />
stability, added to which the spindle runs smoothly and with<br />
low vibration. In addition to the machinery, Mazak and another<br />
partner designed a workholding attachment for the<br />
300 mm (11.811") long, 110 mm (4.331") wide and 30 mm<br />
(1.181") high valve block. The attachment is mounted directly<br />
on the spindle flange, where the chuck is normally. The number<br />
of clampings was consequently reduced from nine to two.<br />
SIT: the company<br />
Almost 40 years of experience in top-quality valve<br />
technology has enabled Walter Schumacher to build up<br />
a solid customer base in almost every industry sector.<br />
The main field of activity is the manufacture of special<br />
valves and customised, stand-alone solutions.<br />
Development, production and distribution are all under<br />
one roof. SIT offers its customers short lead times from<br />
initial contact to the finished product, resulting in<br />
lower costs and direct contact with decision-makers.<br />
The use of modern machinery and specially trained<br />
personnel enables the company to produce large<br />
series as well as one-offs with consistent quality and<br />
in accordance with individual customer requirements.<br />
Each and every valve undergoes quality control. The<br />
workmanship, performance and leak tightness –<br />
up to and including a helium leak test with a report<br />
if required – are carefully checked before the goods<br />
are dispatched. Tested assemblies, including components<br />
such as flow regulators, filters, pressure relief valves<br />
and pressure transmitters, in addition to the valves,<br />
reach SIT customers as a complete package.<br />
Horn takes the top spot<br />
Once the machine concept had been decided, the next step<br />
was the tool planning. “After initial contact was made and the<br />
machining task had been outlined, it quickly became clear<br />
to me that the finishing processing should be performed using<br />
our DTM milling system”, says Horn product manager<br />
Jürgen Schmid. The tool is tipped with a monocrystalline<br />
diamond (MCD) cutting edge. The second cutting edge is<br />
tipped with PCD and is used as a pre-cutter to achieve the<br />
defined allowance of 0.02 mm (0.001") for the MCD. “As well<br />
as Horn, an alternative tool manufacturer was also in the<br />
running. However, Horn solved the task on the first attempt,<br />
while the other manufacturer needed three attempts. This<br />
made our choice clear, not only because we were immediately<br />
satisfied with the result, but also because of how impressed<br />
we were by the company’s expertise. We also use other tool<br />
systems from Tübingen and are very satisfied with them”,<br />
says Walter Schumacher.<br />
The surface milled by the Horn DTM tool system achieved<br />
a measured value of Ra 0.012 µm (4.724409e-7"). The tool<br />
body has a diameter of 125 mm (4.921") and has two cutting<br />
edges – an MCD insert and a PCD pre-cutting insert<br />
mounted opposite each other in the milling cutter body.<br />
The six free seats are fitted with carbide balancing inserts.<br />
The tool is finely balanced at Horn to ensure it runs without<br />
vibration. The insert seats in the DTM body can be adjusted<br />
in the axial direction via an adjusting screw. Every ten-degree<br />
rotation moves the insert seat by 0.01 mm (0.0004"). This<br />
means that the axial run-out of the individual cutting edges<br />
can be adjusted with micron precision. The internal coolant<br />
supply ensures targeted cooling of the contact zone and enables<br />
efficient chip removal. The low mass of the aluminium<br />
body protects the spindle and reduces energy consumption<br />
compared with steel bodies.<br />
no. 3, August <strong>2022</strong><br />
7
cover story<br />
Delicate surfaces<br />
“One difficulty was the large number<br />
of holes drilled into the surface<br />
to be machined. Necessarily, brilliant-finish<br />
milling must be the final<br />
machining operation, as otherwise<br />
very fine chips from drilling, reaming<br />
and thread milling would damage<br />
the reflective mirror surface”,<br />
explains Schmid. “Even fingerprints<br />
can render the sealing surface<br />
unusable later on”, adds Stefan<br />
Schumacher. The interrupted cut<br />
across the drilled holes posed no<br />
problem for the Horn tool. During<br />
processing, the milling cutter moves<br />
once longitudinally over the workpiece<br />
at a speed n = 5,000 rpm and<br />
with a feed rate of v f = 500 mm/min<br />
(19.685"/min). The cutting speed is<br />
v c = 1,960 m/min (6430.446 ft/min).<br />
To reduce re-cutting of the chips,<br />
the tool is set at a minimum lead angle<br />
of 0.008 degree. A commercially<br />
available emulsion is used for the<br />
coolant.<br />
“We are very satisfied with the<br />
performance of the tool. In series<br />
production, we now achieve<br />
surface qualities between Ra 0.012<br />
(4.724409e-7") and Ra 0.014 µm<br />
(5.511811e-7")”, summarises Stefan<br />
Schumacher.<br />
Craftsmanship<br />
To produce surfaces with a mirror<br />
finish, the quality of the tool cutting<br />
edge plays a decisive role. The quality<br />
of the cutting edge is reflected<br />
in the surface to be machined. The<br />
final grinding and polishing of the<br />
MCD cutting edge requires craftsmanship.<br />
Similarly to when cutting<br />
a diamond for jewelery, the finish<br />
grinding of a tool cutting edge for<br />
high-gloss machining is done by<br />
hand. Air-bearing grinding tables<br />
with a top made of solid granite<br />
provide optimal conditions for<br />
grind ing the cutting edges. A micros<br />
cope with 200 x magnification<br />
is used for optical inspection. Un<br />
der this magnification, the cutting<br />
edge must be absolutely free from<br />
imperfections. For grinding MCD<br />
ball nose end mills for high-gloss<br />
machining of freeform surfaces,<br />
Horn developed a grinding machine<br />
that can be used to reliably grind<br />
diameters down to 0.2 mm.<br />
The Horn DTM milling system with MCD cutting edges made<br />
surface qualities down to Ra 0.012 µm (4.724409e-7") possible<br />
(source: Horn/Sauermann)<br />
Polishing the MKD blades is like a craft<br />
(source: Horn/Sauermann)<br />
SIT has been relying on solutions from the tool manufacturer since about 20 years.<br />
“The cooperation for the production of the valve block has once again shown us<br />
why we have Horn as a tool partner. Their know-how impresses us. We would also<br />
like to emphasise the joint cooperation with Mazak engineers. Everyone involved<br />
worked hand in hand and gave everything to solve this difficult machining task,”<br />
says Walter Schumacher.<br />
further information: www.phorn.de<br />
8 no. 3, August <strong>2022</strong>
Eagles do not take flying<br />
lessons from pigeons.<br />
↓<br />
The new Multigrind® Radical:<br />
The predator among the grinding machines.<br />
Haas Schleifmaschinen GmbH<br />
www.multigrind.com
materials & tools<br />
Solid PCD endmills – a new opportunity for<br />
increased productivity for those ready to strike<br />
Example of solid PCD tipped<br />
ball endmill and drill<br />
made on EDGe<br />
Example of solid PCD tipped<br />
ball endmill and drill<br />
made on EDGe<br />
The EDGe is capable of making<br />
solid PCD tipped drills under 1 mm<br />
Used in the right application, a diamond (or<br />
PCD – polycrystalline diamond) cutting tool<br />
can last up to 20 times that of an equivalent carbide<br />
tool. The exciting news is, a new generation<br />
of solid PCD helical endmills and drills made<br />
on ANCA’s EDGe machine is set to further extend<br />
this advantage. There is strong demand<br />
emerging in the 3C (electronics) and aerospace<br />
manufacturing industries for such tools that can<br />
deliver improved productivity and quality in the<br />
finished workpiece.<br />
As a 5-axis CNC machine, the ANCA EDGe with its<br />
rotary EDGe process, is ideally suited to create complex<br />
3D cutting tool forms. ANCA has a heritage<br />
of software development that supports design and<br />
manu facture of complex geometries on rotary cutting<br />
tools using ToolRoom software. In addition to helical<br />
drill points, our latest software release allows customers<br />
to manufacture helical endmill (square, corner radius<br />
and ballnose) forms.<br />
A conventional brazed PCD cutter has a shear cutting edge<br />
that limits cutting performance<br />
10 no. 3, August <strong>2022</strong>
materials & tools<br />
This capability is coming at just the right time for PCD cutting tool<br />
manufacturers, as there is an alignment of market and technology developments<br />
making solid tipped PCD tools economical and desirable.<br />
Users of PCD tools are asking for longer life and better cutting performance<br />
than is possible with a shear cutting edge on a tradi tional<br />
PCD tool. The aerospace and 3C industries in particular, are driving<br />
this. Additionally, the solid PCD tip production processes have matured,<br />
and with that, have become more affordable.<br />
Flexibility sets PCD tipped tools apart<br />
Solid PCD tipped tools offer a number of advantages. Most important<br />
is the complete flexibility in tool geometry. The EDGe machine’s Tool-<br />
Room software allows users to create helical cutting tools, both drills<br />
and endmills, with far superior cutting properties compared to equivalent<br />
tools with brazed planar PCD inserts.<br />
Traditional PCD rotary cutting tools feature flat PCD tips brazed onto<br />
a carbide tool body. While the PCD will extend the life of the cutting<br />
edge, by design the cutting geometry is a shear (straight) edge with a flat<br />
hook face. This geometry inherently limits the performance of the tool.<br />
With solid PCD tipped tools, tool designers can have greater flexibility<br />
to create unique geometries specific to various cutting applications, in<br />
the same way as is done for conventional carbide tools. This applies not<br />
only to the cutting profile, but importantly to flute and gash geometry<br />
which are critical to chip formation and evacuation.<br />
Another important consideration is that while the smallest tool diam<br />
eter for brazed PCD tools is typically 6 mm, solid PCD tipped tools<br />
can readily be made much smaller than this. Micro tools (drills and<br />
endmills) are gaining widespread use in the 3C market with the EDGe<br />
capable of producing drills down to 0.3 mm and milling cutters under<br />
3 mm. Finally, unlike coated carbide tools, these new drills and endmills<br />
can be resharpened many times readily, effectively extending the tool’s<br />
usable life.<br />
ANCA’s EDGe machine has the capabilities to produce these unique<br />
tools. Of all forms of PCD machining processes, rotary erosion, that is<br />
used by the EDGe, is by far best suited to producing solid PCD tipped<br />
drills and endmills. Wire erosion cannot create flute or gash forms, and<br />
laser ablation has highly expensive upfront cost and is ultimately uneconomical<br />
on anything but the very smallest of solid tools.<br />
ANCA’s EDGe has both electrical discharge machining and carbide<br />
grinding capability. This is an important consideration given these solid<br />
PCD tipped tools will naturally require the flute and OD form to extend<br />
into the carbide. With both electrical discharge machining and grinding<br />
capability, one has the choice to select the optimal process for dif -<br />
ferent material removal.<br />
Built on a heritage of solid carbide grinding capability, ANCA Tool-<br />
Room software is renowned for its inherent flexibility and ease of use.<br />
ANCA EDGe is a highly versatile machine that performs equally<br />
well in other applications such as conventional brazed PCD shear tools<br />
and solid carbide grinding. The EDGe machine, with its latest software<br />
capable of producing helical endmills and drills, will reward cutting<br />
tool manufacturers who are quick to pounce on a market that is always<br />
demanding new tools with better price to productivity performance.<br />
further information: www.anca.com
materials & tools<br />
The right tool for high-quality tapping<br />
The Japanese company Yamawa is a world leader<br />
in threading tools manufacturing with four highly<br />
specialized factories all located in Japan that guarantee<br />
the production of 1,400,000 taps per month. The<br />
Z-PRO VU series of taps by Yamawa is especially designed<br />
for use with water-soluble cutting fluid and represents<br />
the optimum solution for tapping on high performance<br />
machining centers. Recently the company<br />
has broadened the range of VU series with new products<br />
and sizes.<br />
With continuous innovations,the company aims to provide<br />
the market with the best threading solutions, from aerospace<br />
and automotive industries to ship building, machine<br />
tools, electric appliance, IT and many other fields. Among<br />
Yamawa’s offer, the Z-PRO series represents the state of the<br />
art of high performance tapping; developed to guarantee<br />
high performance and reliable tapping, as well as extending<br />
tool life significantly thanks to exceptional chip evacuation.<br />
VU series, especially designed for<br />
multifunction machining centers<br />
The VU series, part of the Z-PRO, is a machine tap series<br />
designed to be used in modern multifunction machining centers<br />
and for tapping with either oil or water soluble cutting<br />
fluids, aiming at ensuring the highest quality and flexibility.<br />
VU taps are suitable for the machining of a broad range of<br />
materials, from steel to stainless steel and nonferrous materials,<br />
the tapping speed goes from 10 to 30 m/min, depending<br />
on the application. Taps are made of coated premium powder<br />
high-speed steel (HSSP) based on Yamawa specifications<br />
that ensure excellent wear resistance; the coating is suitable<br />
for water-soluble oil applications and ensures that the tools<br />
have superior heat resistance and longer life than conventional<br />
machine taps. Another strength of Z-PRO VU series is<br />
the special geometry: Yamawa has completely revised the design<br />
of flute shape to target it on medium tap ping speeds; this<br />
allows efficient chip ejection resulting in a lower and more<br />
stable tapping torque and, consequently, longer tool life with<br />
both the use of emulsion and oil.<br />
Part of the VU series are spiral fluted taps for blind holes<br />
(VUSP) and spiral pointed taps for through holes (VUPO),<br />
tools able to deliver top performances, reliability, and quality<br />
in every manufacturing context, from mass production to<br />
small-batch applications.<br />
To show the flexibility and durability of VU taps, a comparative<br />
test ran at 15 m/min cutting speed on a machining center<br />
with rigid holder (synchronized feed). In this application,<br />
two different materials were machined in the same task: C45<br />
and A5052. Lubricant was water-soluble oil and the tap was<br />
the coated spiral fluted Yamawa Z-PRO VUSP M6x1 (tapped<br />
hole diameter of 5 mm, depth 5~12 mm). After tapping 1600<br />
holes in the two materials, the tap was still running while the<br />
competitor’s tap broke after only 480 holes: Yamawa tap has a<br />
longer tool life by 42 %.<br />
The special design and<br />
coating of the VU series<br />
are also efficient in preventing<br />
chipping: in a test<br />
on a M10x1.5 tap machining<br />
C50 at 20 m/min the<br />
wear after tapping more<br />
than 1100 holes shows,<br />
while with a conventional<br />
tap chipping occurs<br />
after 900 holes.<br />
Optimized shape<br />
flute for improved<br />
thread surface finish<br />
Another interesting technical<br />
feature is the optimized<br />
shape of the flute<br />
Taps of Yamawa<br />
Z-Pro VU series<br />
in the chamfer portion of VUPO taps that improves the chip<br />
ejection significantly. When tapping into a through hole on<br />
a machining center, chips often hit the clamping device;<br />
they can cause severe problems such as edge chipping and<br />
oversized threads that lead to poor quality threads. Field<br />
test carried on using VUPO taps with emulsion for tapping<br />
AISI304 steel at 10 m/min demonstrated how the improved<br />
edge sharpness and discharge of chips of Yamawa taps clearly<br />
results to enhanced thread surface finish.<br />
Thanks to its technical innovations Z-PRO, the VU series<br />
of taps has been recognized as a benchmark for high performance<br />
tapping across Europe. Yamawa has recently<br />
broadened the range with new sizes. The VUSP for blind<br />
holes comprises taps up to M24 size for both the M and MF<br />
thread types, while the range of VUPO for trough holes goes<br />
from actual M3~M16 to M2~M24 sizes (from M16 both<br />
the M and MF thread types are available). The VUPO and<br />
VUSP taps are available in stock, also with the long shank<br />
(JIS standard).<br />
The new VUSP CH coated spiral fluted tap with axial<br />
lubrication hole for the use with water-soluble coolant has<br />
also joined the VU series. In these taps the coolant hole<br />
diameter is optimized to allow abundant internal lubrication<br />
for drastic heating and welding reduction resulting in improvement<br />
of the wear resistance and the quality of the internal<br />
thread. VUSP CH taps discharge chips smoothly, guaranteeing<br />
continuous machining and process reliability.<br />
The new VUSP E(1.5P) completes the range. The chamfer<br />
length is 1.5 pitches, making the tool ideal for machining<br />
blind holes where there is little room between the bored<br />
hole depth and the full thread length. Thanks to the unique<br />
flute shape, this type of taps has improved chip ejection and<br />
reduced cutting resistance that allow longer life and excellent<br />
internal threads quality.<br />
further information: www.yamawa.com<br />
12 no. 3, August <strong>2022</strong>
Cubic boron nitride for tough cases<br />
materials & tools<br />
Paul Horn GmbH is expanding its tool portfolio<br />
for machining hard materials and other steels. Tools<br />
tipped with cubic boron nitride (CBN) offer optimised<br />
machining of nickel-based and other superalloys as<br />
well as powder metallurgical and hardened steels. The<br />
ultra-hard cutting material CBN demonstrates its<br />
strengths in smooth cutting and interrupted cutting<br />
when hard turning and grooving.<br />
By including extensions in the standard range for the<br />
Supermini 105, Mini 11P, 229 and 315 systems, Horn offers<br />
the user fast delivery of the desired tool systems from stock.<br />
The Supermini system is available in left and right hand<br />
versions with different corner radii. The CBN-tipped variants<br />
are suitable for internal machining from a diameter of<br />
2 mm (0.079"). Different projection lengths of the solid carbide<br />
bodies are also available. Tools in the Mini family can<br />
be used from an internal diameter of 6.8 mm (0.268") and<br />
are also available in left and right hand versions. The single-edged<br />
tool type 315 is suitable for external grooving operations<br />
from a groove width of 0.5 mm (0.012"). In the cutting<br />
insert system 229 the previous CBN substrate CB 50 is<br />
replaced by the higher-performance substrate CB 35. The<br />
cutting inserts are available with two different corner radii<br />
and cutting widths from 3 mm (0.118") to 6 mm (0.236").<br />
Horn is expanding its tool portfolio with CBN-tipped tools for<br />
machining hard materials<br />
After diamond, CBN is the second-hardest material known<br />
to man. Tools made from CBN wear much slower than<br />
other cutting materials when used properly. This makes it<br />
possible to achieve higher dimensional and shape accuracy<br />
and also means that hard materials (steel up to 70 HRC)<br />
can be machined reliably. There are no different types of<br />
CBN. The difference is the CBN volume fraction, the fillers,<br />
the grain size and the ceramic/metallic binder phase (cobalt/<br />
nickel), resulting in different CBN substrates. Hard machining<br />
with CBN cutting materials is usually done without coolant<br />
because the cutting material has a high heat resistance<br />
and the high temperature within the chip formation zone has<br />
a positive effect. An insufficient supply of coolant or interruptions<br />
in cutting lead to high, thermally induced stresses<br />
in the structure of the indexable insert, causing cracks in<br />
the structure and possibly even destroying the indexable insert.<br />
During hard machining most of the heat generated in<br />
the shear zone is dissipated via the chip. While carbide suffers<br />
a significant loss of hardness at about 800 °C (1,472 °F),<br />
the hardness of CBN remains almost unchanged, even at<br />
temperatures up to 1,200 °C (2,192 °F). Another significant<br />
advantage is chemical resistance, particularly at the prevailing<br />
temperatures.<br />
AMB <strong>2022</strong>, hall 1, booth J10<br />
further information: www.phorn.de<br />
Perspective Change:<br />
3D-lasered<br />
multi-tooth tools<br />
for high-speed and high-quality<br />
machining of hard materials<br />
Visit us:<br />
www.zecha.de<br />
13.-17.09.<strong>2022</strong><br />
Stuttgart<br />
Hall 1 · Stand A47
materials & tools<br />
Top performers for turning hardened<br />
steels and aluminium<br />
It was a quantum leap in the development of machining<br />
technology worldwide when General Electric<br />
first offered polycrystalline diamond cutting edges in<br />
1973, followed 1975 by CBN boron nitride cutting edges<br />
for machining non-ferrous metals – primarily aluminium<br />
– and hardened steels.<br />
With passion, innovation and success, LACH DIAMANT has<br />
been involved since almost fifty years in its now 100-year history.<br />
Many patents bear witness to this until today.<br />
In a special show at AMB in Stuttgart, LACH DIAMANT<br />
will present the favourite products that have become a “must”<br />
in mass production:<br />
→ PCD chip breaker for the process-safe turning of<br />
aluminium the PCD cutting insert with active<br />
chipbreaker (international patents) «IC-plus» world’s best<br />
PCD<br />
chipbreaker<br />
«IC-plus»<br />
world’s best for<br />
process-safe<br />
turning of<br />
aluminium<br />
→ CBN inserts for the finish turning of high-alloy hardened<br />
steels and grey cast iron «CBN-DUO-power»<br />
(tipped with two CBN cutting edges)<br />
AMB <strong>2022</strong>, hall 3, booth D12<br />
further information: www.lach-diamant.de<br />
Flexible changing system reduces inventory and<br />
changeover time significantly<br />
Heimatec, a world leader in live tools, angle heads<br />
and multi-spindle drill heads, announced immediate<br />
availability of its popular u-tec® flexible changing<br />
system on all live tools in the company’s product line.<br />
Tools are now available for the most popular machine<br />
tool models in the market, according to Platinum Tooling<br />
Technologies, Inc. president, Preben Hansen. Platinum<br />
Tooling is the exclusive North American importer. The<br />
company plans to include its u-tec® flexible changing system<br />
on all live tools and angle heads, going forward, according<br />
to Hansen. He notes this design offers the benefits of quick<br />
change, while maintaining exceptional rigidity.<br />
The u-tec® patented changing system allows a standard ER<br />
output live tool to accept various adapters for different applications.<br />
This allows users the ability to have quick changeover<br />
of tools on almost any lathe or mill, using a single tool, without<br />
having to commit to a quick-change system on the initial<br />
purchase. A facemill adapter, for example, can be quickly<br />
positioned into the standard holder, without the need for a<br />
new tool purchase. This significantly reduces inventory costs<br />
as well as changeover time for the busy shop.<br />
The u-tec® system, according to Preben Hansen, “…represents<br />
a real improvement in lathe live tooling design. u-tec®<br />
allows great user flexibility and ensures a solid connection<br />
due to the polygon design built into both the tool and<br />
The typical<br />
live tool adapter<br />
hardware of the u-tec® system<br />
the adapter. This polygon connection helps guarantee the<br />
proper position and alignment of the adapter inside the tool.<br />
Once the insert is properly positioned and the collet nut<br />
is clamped, the cutting tool will have excellent rigidity and<br />
torque transmission.” He further explains the unique collet<br />
nuts on the u-tec® system have internal threading for clamping<br />
stability and that this new tool adapter system enables the<br />
actual cutting tool to be brought into closer proximity to the<br />
bearing, thus further improving performance in use.<br />
Every adapter in the u-tec® system is furnished complete<br />
with the necessary clamping nut and holding wrench, they<br />
are available in various outputs such as arbor, Weldon, ER<br />
extension and blank styles. The u-tec® system is available for<br />
all major turning machines on the market today. Heimatec<br />
currently manufactures over 10,000 live tool types and has<br />
a full inventory at Platinum Tooling, their North American<br />
importer, headquartered in the Chicagoland area.<br />
further information: www.platinumtooling.com<br />
14 no. 3, August <strong>2022</strong>
materials & tools<br />
Supermini Set<br />
Paul Horn GmbH offers users now its proven<br />
Supermini tool holder system with face clamping as<br />
a set, thereby responding to customer requests for<br />
different tooling system heights.<br />
The heart of<br />
metal working<br />
beats in Stuttgart!<br />
The new Supermini set will be presented at AMB <strong>2022</strong> in<br />
Stuttgart, hall 1, booth J10, for the first time.<br />
Horn now offers users its proven Supermini<br />
tool holder system with face clamping as a set<br />
With this holder variant, clamping is not carried out via<br />
the lateral surface of the cutting insert but via a clamping<br />
wedge on the face. This results in a greater holding force<br />
on the insert and thus high rigidity of the entire system.<br />
Furthermore this style of clamping increases repeatability<br />
when changing the insert and provides better utilisation of<br />
the available space. This shows to be a great advantage on<br />
Swiss-type lathes, as the user can change the cutting insert<br />
without removing the tool holder.<br />
GET<br />
YOUR<br />
TICKET<br />
NOW!<br />
The set consists of a round shank holder and three different<br />
clamping elements. The latter are suitable for the three<br />
different insert heights of the Supermini system, 03, 04 and<br />
05. When ordering the desired diameter of the round shank<br />
holder can be selected. Choice of the diameters is 10 mm,<br />
12 mm, 16 mm, 20 mm, 22vmm, 25 mm and 28 mm. Inch<br />
dimensions are available in 1/2", 5/8", 3/4" and 1" diameter.<br />
All sets are available from stock.<br />
AMB <strong>2022</strong>, hall 1, booth J10<br />
further information: www.phorn.de<br />
amb-expo.de
materials & tools<br />
Double feed with<br />
the same axial force<br />
EMUGE offers a new tool to reduce main machining<br />
times: the EMUGE Punch Drill. This high-feed<br />
drill is suitable for machining cast aluminium alloys<br />
with at least 7 % Si content.<br />
The possible drilling depth ranges up to approx. 4 x D, the<br />
nominal diameter range from 4 mm to 8.5 mm. Machining is<br />
carried out with a normal drilling cycle on CNC machines,<br />
cutting speeds and coolant pressures are the same as for<br />
conventional drilling.<br />
An innovative chip breaker helps keeping the chip short<br />
and controlling the machining forces. Newly developed surface<br />
treatments and a hard coating specially designed for<br />
this application enable reliable chip removal and increase<br />
process reliability.<br />
The most impressive feature is that the axial force is actually<br />
halved when this high-feed tool is used with the feed<br />
of the series tool. By increasing the feed at the same speed,<br />
main times are reduced and machine capacities are economised.<br />
The reduced power consumption of the machine is<br />
also in support of sustainability.<br />
The EMUGE Punch Drill helps to conserve resources<br />
In short: the tool benefits from shorter machining times<br />
and a high metal removal rate. Higher productivity and less<br />
strain on resources are positive consequences. The tool life is<br />
comparable to conventional drilling tools despite the higher<br />
feed rate. The superior self-centering capability of the drill tip<br />
enables the best possible positioning accuracy on the holes.<br />
For multi-step-drilling operations, the EMUGE Punch Drill<br />
is also available as a step tool.<br />
further information: www.emuge.de<br />
Innovation in the precision tools sector<br />
At AMB ZECHA Hartmetall-Werkzeugfabrikation<br />
GmbH will be demonstrating how to implement maximum<br />
precision, outstanding quality both in the product<br />
and during the production, and maximum productivity<br />
in micro-machining. New developments and<br />
expanded product ranges guarantee innovative tool<br />
solutions.<br />
Change your perspective:<br />
3D lasered multi-tooth cutters –<br />
MARLIN<br />
Miniature tools, sophisticated tool contours and the machining<br />
of ultra-hard materials can’t be combined? Think again!<br />
Thanks to the latest technological processes and our highly<br />
developed tool expertise, ZECHA is entering a new era with<br />
brand new 3D lasered tools from the MARLIN family. These<br />
specially developed multi-toothed tools, consisting of the<br />
960, 962, 965 and 966 series with their geometrically defined<br />
cutting edges, set the benchmark when machining extremely<br />
hard materials. The combination of high efficiency, quality<br />
and feed rate opens up a new world and makes diverse 3D<br />
shapes and geometries possible for a wide range of applications<br />
– including ultra-hard machining of glass.<br />
IGUANA<br />
In comparison to our competitors’ tools, ZECHA’s IGUANA<br />
tools offer a 400-fold longer tool life in copper, a 15-fold<br />
longer in fibre-reinforced PEEK and a 10-fold longer tool life<br />
in lead-free brass because of their unique fusion of technologies.<br />
Thanks to the innovative laser processing of the diamond<br />
coating, its small diameter multi-cutters shine brightly<br />
as a result of their extreme sharpness, extreme wear resistance,<br />
very long service life and very high process reliability.<br />
Thanks to various design options – spiraled, lasered on both<br />
sides, with or without a cooling system – this tool family can<br />
be used to machine a wide range of applications and the most<br />
demanding materials with smooth surfaces and a performance<br />
of the highest quality.<br />
With the 935 series of the IGUANA family, ZECHA has<br />
yet developed another high-end line. The torus or ball-nose<br />
end mills with spiralling are equipped with a patented cutting<br />
edge clearance (EP 2450427B1*), which is specially designed<br />
for your needs when making moulds.<br />
AMB <strong>2022</strong>, hall 1, booth A47<br />
further information: www.zecha.de<br />
16 no. 3, August <strong>2022</strong>
Successful shift work<br />
materials & tools<br />
Circular saw blades for aluminum composite panels and aluminum profiles<br />
Aluminum composite panels place high demands<br />
on cutting tools. LEUCO has developed special saw<br />
blades with carbide and diamond cutting edges for<br />
these materials. These ensure long tool life even for<br />
demanding production processes. In addition, LEUCO<br />
also offers highly productive and durable tools for<br />
aluminum profiles.<br />
Furthermore, as a manufacturer specializing in tools for<br />
wood, plastics and non-ferrous metals, LEUCO has developed<br />
a program for aluminum composite panels, because<br />
these composite materials are becoming increasingly common<br />
in sectors such as retail store and trade show construction,<br />
as well as window and facade production.<br />
Carbide cutting edges for demanding applications<br />
Cutting and processing of aluminum composite panels are<br />
not difficult when using appropriate tools. LEUCO recommends<br />
selecting saw blades according to the number of<br />
pieces produced and the type of panel. For single cuts of<br />
common composite panels, saw blades with the flat trapezoidal<br />
tooth shape (type “TRF-F-FA”) are the first choice.<br />
LEUCO supplies the TRF-F-FA with cutting edges made<br />
of HL Board 04 Plus carbide. This cutting material, first introduced<br />
in 2017, is particularly resistant to fracture and impact.<br />
Saw blades with this cutting material achieve the longest<br />
edge lives that are currently possible at LEUCO for<br />
tungsten-carbide products. For sawing non-ferrous metals,<br />
HL Board 04 Plus is a good choice.<br />
Saw blades with the TRF-F-FA tooth shape are suitable for<br />
common machines, for example, from Holz-Her or Striebig,<br />
as well as for table saws, for example, from Altendorf, also<br />
without a scoring saw blade. This saw blade can be used<br />
to process the usual composite panels with intermediate<br />
layers of plastic. Such composite panels for construction<br />
applications are usually between 2 mm and 6 mm thick, including<br />
the two approximately 1 mm thick aluminum top<br />
layers. The usual thickness of the panels is 4 mm. The middle<br />
layer is usually made of polyethylene or polypropylene.<br />
Diamond for mineral-filled layers<br />
A special case is aluminum composite panels with mineral-filled<br />
polymers, for example, the ALUCOBOND® and<br />
ALPOLIC® brands. Due to the mineral fillings, these composite<br />
panels achieve very high fire classifications. For such<br />
panels LEUCO recommends saw blades with the HR tooth<br />
shape and polycrystalline diamond cutting edges (DP).<br />
They achieve surprisingly long service lives despite the hard<br />
middle layers. Another important strength of the two tooth<br />
shapes TRF-F-FA and HR are the almost burr-free cuts. This<br />
is one of the most important quality criteria when evaluating<br />
circular saw blades for non-ferrous metals.<br />
Processing of aluminum composite panels in packs is<br />
also extremely demanding. For this purpose, a combination<br />
of DP cutting material and the TRF-F-FA tooth shape<br />
has proven to be the best. This saw blade is sharp and robust<br />
enough to cut several layers of aluminum composite panels<br />
in one pass. At the same time, it achieves a tool life with<br />
which this highly productive type of processing also makes<br />
economic sense.<br />
LEUCO has developed the HW TR-F-K saw blade<br />
especially for aluminum profiles, for non-ferrous metals;<br />
it can be used on chop saws, miter saws and table saws<br />
Chop saw blades for aluminum profiles<br />
Unlike panels, profiles are usually hollow sections. These are<br />
also used in many industries. This includes window and trade<br />
show construction – but also the machinery sector. There,<br />
aluminum profiles serve as the basis for the construction of<br />
fixtures and machine enclosures. In any case, before mounting<br />
the profiles must be cut accurately, and, for example,<br />
manufacturers of windows with aluminum frames usually<br />
use miter cuts. For such work, LEUCO has developed<br />
cross-cut and miter saw blades designed for light metals.<br />
The newest development in this area is the HW TR-F-K saw<br />
blade. It can be used on cross-cut and miter saws as well as<br />
table saws. It is intended for cutting non-ferrous metals such<br />
as aluminum, copper and magnesium. The HW TR-F-K is<br />
specially designed for machines from Kaltenbach, Elumatec,<br />
Emmeggi, RAPID and Eisele as well as for companies that<br />
process such profiles in large numbers. This gives them a tool<br />
that produces the best quality with exceptionally long tool<br />
life. Wall thicknesses of profiles can be up to 5 mm. The saw<br />
blade achieves its highest productivity with thicknesses of<br />
2 to 3 mm. The HW TR-F-K is available with diameters from<br />
350 to 600 mm.<br />
further information: www.leuco.com<br />
no. 3, August <strong>2022</strong><br />
17
materials & tools<br />
LACH DIAMANT looks back on 100 years – 13 th part<br />
Poly – poly – or what?<br />
Forty years of spark erosion for efficient<br />
PCD machining – utilizing sparks over grinding<br />
Horst Lach, managing director and CEO of<br />
LACH DIAMANT, agreed to write an ongoing series<br />
of articles about the development of diamond and CBN<br />
tools and grinding wheels in modern industries.<br />
Horst Lach is known as a true industry veteran, and<br />
we are excited to have this pioneer of technology share<br />
some insights from his over 62 years of professional experience<br />
in the diamond tool business. This time our<br />
focus is on “using sparks instead of grinding”.<br />
In 1978 Horst Lach had a truly sparkling idea. Initially, it<br />
led to efficient machining and forming of polycrystalline diamonds.<br />
Thanks to this revolutionary invention it was possible<br />
to implement new technologies, based on newly created<br />
diamond tools. For example the machining of wood and plastics<br />
in the furniture and kitchen cabinet industry, as well as<br />
laminate and parquet flooring, circuit board, automobile and<br />
automotive accessories industries and in many other areas.<br />
Controlled impact<br />
Up to 1978 it was traditionally thought, that only diamonds<br />
could be used for machining diamonds. The discovery of<br />
spark erosion and of the so-called EDG grinding method<br />
(rotation procedure – electrical discharge grinding) by Horst<br />
Lach, ignited a new, until then unimaginable, and much<br />
wider distribution and use of PCD – a material introduced to<br />
the market in 1973.<br />
Horst Lach had a sparkling idea<br />
Horst Lach utilized a mere 0.5 % of traceable cobalt present<br />
in this polycrystalline compact material which otherwise<br />
consists of 99.5 % pure diamond (during diamond synthesis,<br />
single diamond grains with a size of 0 to for example 35 µ<br />
are compressed under high pressure and heat and thus stimulated<br />
to grow). Under the controlled impact from electric<br />
sparks, single diamond grains are stimulated to break free<br />
from the grip of the electrically conductive cobalt.<br />
Pioneering PCD tools<br />
LACH DIAMANT, having its 100 th anniversary, since Horst<br />
Lach’s father, Jakob Lach, founded the company, did not only<br />
use electric sparks for the development of pioneering PCD<br />
tools. In order to create an efficient, precise procedure for<br />
forming functional cutting edges on tools, the electric spark<br />
had to be integrated with the diamond blade or the tool-moving<br />
axes and edge controlers, respectively.<br />
This was the beginning of LACH DIAMANT as a machine<br />
ma nufacturer. Today, in <strong>2022</strong>, automatic LACH DIAMANT<br />
grinding machines for the production and sharpening of polycrystalline<br />
diamond tools can be found all over the world.<br />
A new generation of superior automatic LACH DIAMANT<br />
grinding machines – capable of using graphite and/or copper<br />
as the respective ideal rotation electrode – are now part of<br />
the LACH DIAMANT machine programme.<br />
Example: grinding of diamond saw blades<br />
with a programme for multi-production<br />
Individual presentations available<br />
At GrindingHub in Stuttgart it was possible to see all innovations<br />
and extras of the LACH DIAMANT EDG-plus-sparksharpening-machines<br />
at the tradeshow – e.g. the «Dia-2200-<br />
mini» and the special «contour-profiled» model for superior<br />
profiling of metal-bond diamond and CBN grinding wheels.<br />
For this reason, LACH DIAMANT invites all interested diamond<br />
grinding companies to an individual presentation at<br />
our grinding center in Hanau.<br />
Horst Lach<br />
further information: www.lach-diamant.de<br />
18 no. 3, August <strong>2022</strong>
Gleason Corporation announces the passing of<br />
James S. Gleason, former chairman and CEO<br />
news & facts<br />
It is with great sadness that we announce the pass ing of<br />
James S. Gleason, a Gleason board member and former<br />
chair man and CEO of the company, who died on<br />
June 17 th at the age of 88.<br />
Being a great grandson of the company’s founder William<br />
Gleason he contributed to the company in various roles, continuing<br />
to serve as a director on the board up until his death.<br />
1959 he started working in the company, holding various<br />
positions to become CEO in 1981 (until 2002), and during<br />
that time the company went through significant transformations,<br />
more than doubling in size both through organic<br />
growth and acquisition. The company then recommitted to<br />
its strategy of global leadership in gear technology, broadening<br />
its range of products and further expanding its geo -<br />
graphic manufacturing footprint. In 2000 the company also<br />
returned to private ownership (from a publicly traded company<br />
on the NYSE).<br />
Beyond his accomplishments in the company he held leadership<br />
positions in industry trade organizations along with<br />
board representation in various business, social, charitable,<br />
and educational organizations.<br />
further information: www.gleason.com<br />
Change in the management<br />
of the LMT Tools Group<br />
Mr. Roland Benter took over the role of the CFO of the<br />
LMT Tools Group as of August 1, <strong>2022</strong>. He succeeds<br />
Mr. Jochen Ohler who will leave the company on<br />
December 31, <strong>2022</strong>, by best mutual agreement.<br />
Mr. Roland Benter will succeed Mr. Jochen Ohler in the role<br />
of the CFO of the LMT Tools Group as of August 1, <strong>2022</strong>.<br />
Mr. Benter has extensive experience from senior financial<br />
positions as well as commercial leadership roles including<br />
managing director and consultant with mid-sized industrial<br />
and automotive suppliers. He worked for several years in<br />
the USA and India, has extensive knowledge in the management<br />
of company transactions and a high level of competence<br />
in process management to decisively advance the further<br />
development of LMT Tools<br />
from a financial, commercial<br />
and legal point of view.<br />
His motivating and congenial<br />
manner set him apart.<br />
Jochen Ohler was manag -<br />
ing director and CFO since<br />
June 2018. He has con tribut -<br />
ed significantly to shap ing<br />
the successful business of<br />
the LMT Tools Group.<br />
further information:<br />
www.lmt-tools.com<br />
Roland Benter<br />
took over the role of the<br />
CFO of the LMT Tools Group<br />
as of August 1, <strong>2022</strong><br />
Ex-Kuka executive Till Reuter joins forces<br />
with NEURA Robotics<br />
Since the start of automatica <strong>2022</strong>, NEURA Robotics<br />
has been shaking up the industry with a multitude of<br />
world premieres. Now the Swabians are announcing a<br />
small sensation that is likely to cause a stir way beyond<br />
the automation scene. Till Reuter, former CEO of Kuka<br />
and most recently chairman of the supervisory board<br />
at the Müller Group, has literally let himself get carried<br />
away by the doer attitude of the robotics pioneers into<br />
a future that has already begun at NEURA Robotics.<br />
So NEURA founder and CEO David Reger once again proves<br />
that he leaves nothing to chance on his way to becoming the<br />
man at the helm of a leading company. No one would have<br />
believed that Reuter would ever add another robotics chapter<br />
to his vita after the mega success with Kuka – so this alliance<br />
means a great deal in the automation scene.<br />
Now the experienced business leader is backing David<br />
Reger, 20 years younger, with all his know-how and an impressive<br />
global network – another indication of the potential<br />
the cognitive robotics “Mady by Neura” holds. In record timing<br />
Reger’s team has succeeded in closing major innovative<br />
gaps in robotics and has laid the foundation for the everyday<br />
use of robots alongside humans.<br />
With the goal of revolutionizing the world of robotics,<br />
David Reger won over approximately 20 specialists and an<br />
investor for NEURA Robotics back in 2019. After just three<br />
years, the Metzingen-based company presented the world’s<br />
first robot that – thanks to cognitive abilities and humanlike<br />
senses such as seeing, hearing and feeling – is able to act<br />
and learn independently – in almost any environment.<br />
further information: www.neura-robotics.com<br />
no. 3, August <strong>2022</strong><br />
19
news & facts<br />
LACH DIAMANT – 100 Years<br />
Tradition. Passion. Innovation<br />
part 1: How it all began …<br />
“When I held my first diamond in my hand in 1908, I<br />
would not have imagined that one day diamonds would<br />
not only be used in the automobile industry but also<br />
for the machining of wood and plastics”. Jakob Lach,<br />
the company founder, said this on camera in 1980.<br />
It would become the preface for the first presentation<br />
of a new technique for machining wood and plastics<br />
– using diamonds as cutting material – the Dia<br />
Tool. This video, with audio translated into multiple<br />
languages, has lost none of its relevance for the choice<br />
of appropriate tools within the furniture, flooring and<br />
plastic industries, it can be viewed at:<br />
https://bit.ly/LACHDIAMANT<br />
In the 1980’s this video might have reached an interested<br />
audience of millions of viewers at the international wood and<br />
plastic trade shows, for example in Hanover, Milan, Atlanta,<br />
Los Angeles and even in Beijing.<br />
Despite his advanced age my father, Jakob Lach, was very<br />
interested in all of the new, revolutionary technologies available<br />
for diamonds, even though they were “only synthetic”<br />
like the polycrystalline diamond. Jakob Lach was fourteen<br />
years old the first time he held a diamond in his hands as a<br />
young diamond grinder apprentice.<br />
Diamond cutting as a trade<br />
Born in Rückingen/today Erlensee, Jakob was the oldest of<br />
four brothers and one sister. The parents operated a small<br />
farm.<br />
Company founder Jakob Lach<br />
(photo taken in 1980)<br />
In 1908 diamond cutting in Germany, to be exact, the cutting<br />
of natural diamonds (brilliants), had become an official<br />
trade in the last twenty years, with its center in Hanau<br />
on the Main and along the river Kinzig. The pioneer who initiated<br />
the cutting of diamonds in Hanau was Friedrich Houy.<br />
January 1874 he achieved a breakthrough with a self-constructed,<br />
water-propelled casting disc. He had succeeded<br />
and could now cut diamonds, and he even shared his<br />
newly gained know-how. Word spread quickly in parts of<br />
Palatinate, in Idar-Oberstein, in the Odenwald area, the<br />
Kinzig valley, in Hanau of course, and all the way from<br />
Antwerp to Amsterdam.<br />
People came to Mr. Houy in Hanau to learn, and later started<br />
their own small cutting businesses. Hanau became the<br />
center of diamond cutting. Until the beginning of World<br />
War I several thousands of diamond cutters were employed in<br />
Hanau and the surrounding areas.<br />
A perfect decision<br />
Young Jakob Lach must have had a good master during his<br />
apprenticeship at Heckman, because from now on his life was<br />
focused on diamonds, with all its facets. This became apparent<br />
after the first world war. After serving in the Carpathians<br />
during the war and being wounded, he was – like so many<br />
others – without a job after the war. Nobody was interested in<br />
manufacturing diamond jewellery at that time; he did a twoyear<br />
apprenticeship as a merchant.<br />
Apprentice training as diamond polishers back then –<br />
exemplary and unique for diamond shops at that time<br />
A business registration from December 1919 in Langendiebach/today<br />
Erlensee shows that Jakob Lach registered a<br />
retail business for cigars. His first step to being a fully qualified<br />
merchant and entrepreneur? Merchant school in the<br />
morning and salesman in the afternoon? The decision to<br />
target “diamond cutters” as his cigar customers turned out<br />
to be the perfect choice for his further career. He still knew<br />
a few diamond-cutting shops in and around Hanau which<br />
20 no. 3, August <strong>2022</strong>
news & facts<br />
the group who should be as “neutral” as possible. They chose<br />
Jakob Lach. He was well known, a good communicator, and<br />
he knew something about diamond cutting. In 1922 a small<br />
group of travellers, with their speaker Jakob Lach, went to<br />
visit the diamond company of Joseph Asscher (Amsterdam<br />
Royal Asscher Diamond Company), already well renowned<br />
since 1902, to secure some new orders.<br />
My father told me that Mr. Asscher greeted them personally.<br />
Yes, he had enough diamond material to have it cut to<br />
brilliants in Hanau, he was seriously interested. They could<br />
immediately take a large batch with them, but one of the<br />
Hanau representatives would have to sign a personal pledge<br />
of responsibility. After a brief discussion it turned out that<br />
none of them wanted to give such a personal guarantee for<br />
the others. So the delegation returned empty-handed.<br />
Excerpt of business registration, 1919<br />
had hesitatively restarted business with the help of re turnees<br />
from war. He visited them on his bicycle. He “chatted” a<br />
little here and there, looked over the grinders’ shoulders and<br />
learned to distinguish the good craftsmen from the lesstrained<br />
diamond cutters.<br />
From then on Jakob was known as frequent “guest” at<br />
all diamond cutting shops he visited. The closer the 1920’s<br />
came the less work – i.e. materials – was available for diamond<br />
cutting shops, so as to keep their cutters employed.<br />
Reparations, as demanded by the victorious powers in the<br />
treaty of Versailles after World War I, did the rest. At that<br />
time the German Reich resorted to printing more and more<br />
money, and circulation reached sky-high numbers, up to<br />
tens of trillions. This went so far that in 1923/24 paper mills<br />
could no longer meet the demand of the money printing<br />
machines, so companies had to use value vouchers to substitute<br />
money.<br />
September 1922, due to continuous currency fluctuations,<br />
it was reported that official bodies set prices in-kind; in<br />
Weimar and Naumburg, for example, tuitions, electricity, gas<br />
and doctors’ fees were paid in-kind. I have been told that in<br />
this time the owners of diamond cutting shops got together<br />
in order to try to find a common solution.<br />
From the perspective of potential customers in Holland<br />
and Belgium it was then advantageous to place orders in<br />
the German Reich; wages were low and there was no shortage<br />
of workers. All in all simple, if the diamond business, due<br />
to the quickly resulting high value, was not built on a special<br />
principle: trust!<br />
On the way to Amsterdam<br />
The consulting Hanau entrepreneurs thought the same.<br />
In preparation for their excursion to a potential prospective<br />
customer in Amsterdam, they agreed to select a speaker for<br />
You are my man, Mr. Lach<br />
Jakob Lach, now 28 years old, had listened to all of this,<br />
thought about it, and decided to ask his father whether he<br />
would pay out his share of the inheritance. Jakob Lach returned<br />
to Amsterdam with a few gold marks in his pocket,<br />
this time on his own. He offered Joseph Asscher his inheritance<br />
as a guarantee so that he could take the diamond<br />
material with him in order to save jobs. Apparently Mr.<br />
Asscher was very touched by the young man’s offer. He<br />
answered along the lines of “…you will understand that<br />
the amount you offer is not sufficient as a guarantee for the<br />
value of the stones you want to take with you. But I like you.<br />
I trust you. You are my man, Mr. Lach.”<br />
So Jakob Lach returned to his new office on Glockenstrasse<br />
in Hanau with a large quantity of diamonds* to be cut. If we<br />
want to put it that way, this was the founding date of today’s<br />
Jakob Lach GmbH & Co. KG, now LACH DIAMANT®.<br />
*note:<br />
The rough diamonds were entrusted to the<br />
contractor’s (in this case Jakob Lach’s) safekeeping.<br />
The contractor’s job was now to view the diamonds<br />
one by one and, when e.g., cutting them to brilliants –<br />
57 facets, board included – to achieve the best<br />
possible weight in carat (1 ct = 0.2 gram).<br />
A weight loss of approximately 55 % was deemed<br />
acceptable when cutting brilliants. Each stone which<br />
could be cut with a smaller loss than 55 % would<br />
increase the profit or the resulting final net weight.<br />
As a general rule, business partners would split the<br />
difference between the accepted weight loss of 55 %<br />
and the final net weight; in addition to the calculated<br />
costs (wages) for polishing the diamonds the contractor<br />
was paid his share as a bonus. This was a win-win<br />
situation for both partners. The bigger the contractor’s<br />
know-how when viewing the diamond material before<br />
cutting, the more appealing it was for the client to<br />
enter a lasting business relationship with him.<br />
no. 3, August <strong>2022</strong><br />
21
news & facts<br />
Prevailing in difficult times<br />
His hour had come. Now Jakob Lach could use all his knowhow.<br />
His experience as diamond cutter, and equally important,<br />
from his days as a salesman, his expertise in judging<br />
a cutter’s professional skills which can vary greatly between<br />
individuals.<br />
First company excursions 1923/1924:<br />
a bus trip to Alzenau (lower Franconia)<br />
The available batches were examined stone by stone and<br />
then transferred to different cutting shops especially chosen<br />
for the job; at first this was necessary, because he did not<br />
have his own diamond cutting business. However this would<br />
change quickly, as documented on photographs of the first<br />
company outings around 1923/24.<br />
The exceptionally well-equipped diamond cutting and<br />
polishing shop was located in this timber-framed house,<br />
renovated in 1935, destroyed March 19, 1945<br />
that during this high time of the mid and late 20’s some diamond<br />
cutters only worked four days a week.<br />
Until the end of the 1930’s Jakob Lach could employ approximately<br />
600 diamond cutters. Half of them in shops<br />
he now owned – in Langendiebach/today Erlensee, Nieder-<br />
Rodenbach and finally in Hanau, Steinheimer Strasse/corner<br />
Römerstrasse; the latter a timber-frame building, beautifully<br />
restored by Jakob Lach (which unfortunately fell victim to the<br />
destruction of Hanau).<br />
Another estimated 300 diamond cutters were employed<br />
in sub-contractor shops in Palatine (Idar-Oberstein), the<br />
Odenwald area and far into the Kinzig valley. The great<br />
“depression” at world markets at the end of the 20’s and<br />
the beginning of the 30’s required creative means of payment<br />
– payment in-kind, became more and more common.<br />
Diamond cutting shop in Langendiebach/today Erlensee<br />
at the end of the 1930’s<br />
Despite excessive inflation and general unemployment it<br />
may be noted, that from 1922/23 onward the diamond cutting<br />
profession was doing well, if not very well. Of course<br />
it was fortunate, that the clients were not from within the<br />
German Reich, but from Holland or Belgium. Invoices were<br />
not issued in Reichsmark but in the clients’ currencies or<br />
US dollars. This brought in foreign currencies, independent<br />
of the turbulent situation in Germany. This meant that also<br />
workers were well paid. Contemporary witnesses even report,<br />
It is known that Jakob Lach had to accept “industrial<br />
diamonds” from a Belgian customer as payment instead of<br />
currency. Possibly the beginning and “push” towards the<br />
diamond tool as the future business purpose. The extent of<br />
these alternative payments in-kind must have been so extensive<br />
(since 1936), that Jakob Lach now registered his business<br />
under the trade name “German Industrial Diamond Retail<br />
Jakob Lach” (Deutscher Industrie-Diamanten-Vertrieb Jakob<br />
Lach), with represantives in the Madgeburg/Chemnitz/<br />
Leipzig area (previously known as the machine construction<br />
triangle) and Hessen/Saarland; companies like Opel<br />
Rüsselsheim were among his customers.<br />
How does this story continue? Find out more in Horst<br />
Lach’s next article…<br />
Horst Lach<br />
further information: www.lach-diamant.de<br />
22 no. 3, August <strong>2022</strong>
news & facts<br />
Strategic partnership<br />
The headquarters of TSCHUDIN AG<br />
in Grenchen, Switzerland<br />
TSCHUDIN AG, a global technology leader in highprecision<br />
centerless cylindrical grinding, and the<br />
UNITED GRINDING Group, one of the leading<br />
manufacturers of precision machines for grinding,<br />
eroding, lasering, measuring and combination machining,<br />
are entering into a strategic partnership<br />
involving cross‐ownership.<br />
The aim is to provide their customers with even more comprehensive<br />
support by offering complementary grinding<br />
solutions and using shared sales networks. TSCHUDIN<br />
AG specializes in the manufacturing and global sale of<br />
high‐precision centerless cylindrical grinding machines.<br />
Thanks to the strategic partnership with the international<br />
UNITED GRINDING Group, which offers a wide range of<br />
grinding solutions, from surface and profile grinding to cylindrical<br />
grinding and tool processing, the cus tomers of both<br />
companies benefit from a complementary pro duct portfolio.<br />
The companies continue to operate economically independently,<br />
but benefit from additional synergies in sales.<br />
“The UNITED GRINDING Group is globally strongly<br />
positioned. With the foundation of our TSCHUDIN sales<br />
company in China in 2019 we further expanded our international<br />
presence. We want to continue on this path,” says Urs<br />
Tschudin, shareholder of TSCHUDIN AG.<br />
“We are delighted to be working with TSCHUDIN as a<br />
strong partner who ideally complements our range with<br />
its centerless grinding machines. As part of this strategic<br />
partnership, we provide the complete range of cylindrical<br />
grinding machines to our customers,” says Stephan Nell,<br />
CEO of the UNITED GRINDING GRINDNG Group. “We<br />
look forward to a close long‐term partnership.”<br />
further information: www.tschudin.swiss<br />
Scansonic MI takes over<br />
its own sales efforts<br />
Scansonic MI, one of the world’s leading manufacturers<br />
of laser processing optics, is reorganizing its<br />
global sales structure.<br />
Dr. Axel Luft<br />
As of July 1, the company is working with its own branch<br />
offices in its key markets of Germany, China and the USA.<br />
Sales activities in the rest of the world are supported by<br />
experienced sales partners and distributors. In recent months<br />
the Scansonic sales team has been significantly expanded and<br />
restructured to support this new arrangement.<br />
These efforts are part of Scansonic’s continued growth<br />
strategy. The company’s products for laser-based metal<br />
processing require intensive consultation, and are generally<br />
adapted to each customer’s individual production processes.<br />
Dr. Axel Luft, managing director sales & marketing<br />
at Scansonic, explains the benefits for customers:<br />
“With this new structure, we are now able to directly provide<br />
to our customers the technical knowledge and service<br />
they need. Our experienced sales force keeps close to our<br />
customer base around the world, and also works closely with<br />
Scansonic specialists from the product teams and the<br />
application laboratories.”<br />
further information: www.scansonic.de<br />
no. 3, August <strong>2022</strong><br />
23
news & facts<br />
academy/fairs<br />
New Grinding academy launched<br />
UNITED GRINDING and TITANS of CNC, a manufacturing<br />
group of part-makers, influencers and educators,<br />
have collaborated to launch the all-new<br />
Grinding Academy.<br />
Much like TITANS’ existing machining and aerospace academies,<br />
the Grinding Academy will offer free online courses for<br />
teaching and training the next generation of machinists.<br />
“We’re so excited to be teaming with TITANS of CNC<br />
on their Grinding Academy,” said Paul Kössl, global head<br />
of marketing and business development at UNITED<br />
GRINDING Group. “The precision and quality made possible<br />
by CNC grinding is something that more manufacturers<br />
should know about. The academy will showcase all of<br />
that power and potential, while also teaching viewers how to<br />
harness it.”<br />
TITANS of CNC has four UNITED GRINDING machines<br />
on its shop floor in Texas: the BLOHM PLANOMAT XT profile<br />
grinder, the STUDER favorit and STUDER S41 cylindrical<br />
grinding machines, and the WALTER HELITRONIC<br />
VISION 400 L tool grinder. These machines will be the first<br />
tools used to create content for the Grinding Academy. The<br />
Grinding Academy launched in June <strong>2022</strong>.<br />
further information:<br />
www.titansforgrinding.com // www.grindingacademy.com<br />
TIMTOS 2023 to unveil Metaverse and EV<br />
The world’s third largest machine tool show, Taipei<br />
International Machine Tool Show (TIMTOS), scheduled<br />
for March 6 - 11, 2023, will debut innovations and<br />
applications in EV and Metaverse at Taipei Nangang<br />
exhibition center halls 1, 2 and TWTC hall 1.<br />
Since 2019 TIMTOS became the third largest machine tool<br />
show in the world. Notably, themed with “Green Machine<br />
Tools,” “Smart Machinery,” “Flexible Manufacturing,” and<br />
“Digital Simulation.” TIMTOS 2023 is returning to feature<br />
innovations and applications in EV and Metaverse sectors.<br />
The exhibition will be also showcasing a full line-up of hybrid<br />
events, including online and offline procurement matchmaking,<br />
live broadcasting, forums and seminars. It is worth<br />
noting that, aside from a physical trade show, an online exhibition<br />
will also be available for one month.<br />
The show will present the ecosystem of metal processing,<br />
from key components to smart manufacturing solutions. According<br />
to the organizer TAITRA, TIMTOS will focus on the<br />
issue of “low-carbon supply chains.” Smart solutions that integrate<br />
the concepts of digitalization and carbon reduction<br />
will be highlighted at the show.<br />
Taiwan ranked third in the world’s machine tool exports in<br />
2021, total exports of machine tools in 2021 reached US $ 2.78<br />
billion, a phenomenal increase by 29.1 % compared to 2020.<br />
What’s more, markets recorded more than 50 % growth in<br />
Turkey, the Netherlands and Italy. Unsurprisingly, in anticipation<br />
of continuing global demand, Taiwan machine tool<br />
outputs will increase in the coming while the supply chain<br />
restructuring has generated new business opportunities.<br />
further information: www.timtos.com.tw<br />
24 no. 3, August <strong>2022</strong>
fairs<br />
news & facts<br />
A stable trend towards automation<br />
in the metal cutting industry<br />
Since years automation has kept manufacturing costs<br />
low and processes stable for metal working businesses<br />
carrying out serial production. Nowadays, however, the<br />
market requires a high degree of product individualisation,<br />
resulting in smaller batch sizes. The benefits of<br />
automation are therefore particularly welcome when it<br />
comes to implementing flexible production processes<br />
for small quantities.<br />
The following article provides examples of the solutions to<br />
be presented by exhibitors at the International Exhibition for<br />
Metal Working (AMB) in Stuttgart September 13 - 17, <strong>2022</strong>.<br />
The market for automation, robotics and handling technology<br />
will continue to grow. The AMB exhibitor Grob is convinced<br />
concerning five-axis machines. Grob believes that the<br />
machines will have integrated additional NC axes, to provide<br />
additional options such as feed operations. Turning and milling<br />
machines with hydraulic clamping will combine different<br />
types of machining with the possibility of automation. Grob<br />
sees automation concepts moving further in the direction<br />
of industrial robots to replace more rigid concepts and integrate<br />
additional operations such as deburring, cleaning and<br />
assembly. These developments are already playing an important<br />
part in the further development of universal machines<br />
and automation solutions, and that will continue.<br />
Fast mechanical connection and communication<br />
Flexibility is a top priority for clamping technology manufacturers<br />
too. The AMB exhibitor Schunk can pride itself on offering<br />
quick, simple automation solutions using lightweight<br />
robots. The MTB application kit is designed to provide an<br />
easy introduction to partial automation with cobots. It can<br />
be used to load machines, execute general handling tasks or<br />
quality assurance or even carry out assembly steps. Schunk<br />
also offers single-grip kits that automatically load machines<br />
even in restricted spaces. The double-gripper kit, on the other<br />
hand, loads and unloads on a cycle, thereby increasing machine<br />
productivity. In the cutting machine itself the clamping<br />
force block kit ensures a frictionless interplay between the<br />
gripper and automated clamping force block.<br />
Existing machines to be automated<br />
Also the clamping technology experts at Hainbuch move towards<br />
automation, and not just for new systems. Loading robots<br />
that can perform simple setup tasks such as fitting the<br />
chuck head, the clamping device or tools also add increasingly<br />
to the automation of existing machines. Hainbuch will be<br />
bringing its AC line for automated changing of clamping devices<br />
on machine tools specially to AMB in September. AC,<br />
which stands for Automated Change, enables the automatic<br />
setting up and production of workpieces with different clamp -<br />
ing diameters, clamping profiles and clamping depths. A set<br />
up robot cell is on display, showing a complete automation<br />
solution for manufacturing cells for milling, turning, grinding<br />
or assembly. This will allow visitors to see the full picture,<br />
from clamping device, robot cell, assembly device, gripper<br />
and mounting to sensors and software.<br />
Collaborative and lightweight<br />
The robot manufacturer Fanuc also sees high demand for collaborative<br />
robots on the European market. Shinichi Tanzawa,<br />
president and CEO of the Fanuc Europe Corporation, is confident<br />
of his position at AMB. The company has recently expanded<br />
its product range to include three new collaborative<br />
lightweight robots from the CRX series. These cobots supplement<br />
Fanuc’s existing CR and CRX cobot product line, which<br />
now comprises a total of 11 models that can handle loads<br />
from 4 to 35 kg.<br />
Impossible without software<br />
Intelligent software is the key to successful automation for<br />
the complete machining provider WFL Millturn Technologies.<br />
In combination with suitable automation solutions, it not<br />
only loads and unloads workpieces, it also fully automates the<br />
setup of processing machines with tool and clamping device<br />
changes. The automation expert Frai, part of WFL Millturn,<br />
is developing highly flexible robot systems for this purpose.<br />
At AMB <strong>2022</strong> WFL will be specially showcasing its new<br />
turning, drilling and milling center M20-G Millturn with<br />
gear skiving technology, the intCELL automation solution<br />
and integrated sensors. Using integrated loading, WFL<br />
has reduced space requirements by 50 % compared to<br />
those of a conventional manufacturing cell. The integrated<br />
loading of the M20-G is designed for chuck parts with<br />
Ø 300 mm and workpiece weights of up to 15 kg. For shaft<br />
parts it can take a workpiece Ø 100 mm and a workpiece<br />
length of 300 Ø mm.<br />
Maximising autonomous running time<br />
Hermle offers automation solutions ranging from easy-touse<br />
pallet changers and handling systems for part stocking<br />
using pallets to premium solutions with a diverse range of<br />
robot systems and, increasingly, linear chains, as head of<br />
marketing, Udo Hipp, explains at the trade press conference<br />
before AMB.<br />
The RS 1 robot system is a fully fledged combination cell<br />
for pallet and workpiece automation. The goal is flexibility<br />
and productivity: The rack storage concept ensures a particularly<br />
high autonomous running time, while gripper and tool<br />
changes take place automatically and the fully fledged setup<br />
station allows pallets and workpiece carriers to be set up<br />
while the machine is running. According to Hipp this makes<br />
the RS 1 the perfect automation solution for many businesses.<br />
The robot system can be used with one or with two machines<br />
connected together for maximum output. It can also be converted<br />
from one to two machining centers or expanded with<br />
a third rack module, a washing system, a measuring machine<br />
or a driverless transport system (DTS).<br />
further information: www.amb-messe.de<br />
no. 3, August <strong>2022</strong><br />
25
processes<br />
High precision HSC machining in mold making<br />
for medical technology<br />
Excellent results in graphite, copper<br />
and hardened steels<br />
The production of injection molds for medical<br />
technology is increasingly in focus, due to the current<br />
situation. Globally the demand for medical products<br />
is growing rapidly. On top of increasing production<br />
capacities, special attention is also being paid<br />
to tolerances and surface finishes. With this in mind<br />
the machine tool supplier GF Machining Solutions and<br />
the precision tool manufacturer ZECHA Hartmetall-<br />
Werkzeugfabrikation GmbH have committed themselves<br />
to a project that examines four different automated<br />
manufacturing processes for injection molding,<br />
their qualities and running times.<br />
Graphite electrode (GF Machining Solutions)<br />
Klaus Bruder (ZECHA; left),<br />
Alexander Siegmund (GF Machining Solutions)<br />
The GF Machining Solutions machining equipment and<br />
ZECHA mills offer four cost-effective options with different<br />
surface finishes for the implementation of cavities in a mold<br />
insert made of 1.2343 with a hardness of 52 HRC. The first<br />
manufacturing process for producing a cavity is EDM, using<br />
a graphite or copper electrode. This complex manufacturing<br />
process consists of hard milling of the mold insert, electrode<br />
milling and sinker EDM. The process of producing an<br />
injection mold, using a graphite electrode, takes just under<br />
57 minutes in total, but has many stages. Using the ZECHAmanufactured<br />
tools from the SEAGULL® 1) family on the GF<br />
machines, the Mikron MILL S 600 U and the FORM X 600,<br />
users benefit from tolerances of ± 0.005 mm as well as surface<br />
finishes of Ra 1.6 µm and VDI 24. It is the polymer concrete<br />
machine bed with a high thermal inertia and excellent<br />
dampening properties that makes the Mikron MILL S<br />
series so special. All five axes are equipped with direct high<br />
precision drives (X-, Y-, Z-, B- and C-drives) and thus enable<br />
high speeds of up to 100 m/min and µ-accurate positioning.<br />
Thanks to a spindle with OptiCool or CoolCore technology,<br />
the sophisticated temperature management system with<br />
its cooling circuits ensures the optimum cooling of all heat<br />
sources and the machine bed. The stable thermal system, the<br />
integrated automation and the high-performance guarantee<br />
process reliability, superior productivity and maximum part<br />
precision.<br />
SEAGULL® 1) tools are highly stable ball and torus mills<br />
with an extremely short cutting edge and special geometry to<br />
minimize the cutting pressure in graphite electrode production.<br />
The patented (EP 2 540 427 B1/DE 10 2019 122 039 B31),<br />
very short cutting edge of the SEAGULL® mills together with<br />
its specially developed combination of carbide, diamond<br />
coating and geometry, enables the smooth milling of graphite<br />
and other hard-brittle non-ferrous materials in dry and<br />
wet machining. SEAGULL® high end mills from the 567 and<br />
577 series especially offer small tolerances. Each tool is measured<br />
and the packaging is labeled with the actual values. The<br />
SEAGULL® quality mills of the 568 and 578 series are available<br />
for price-aware users who focus on excellent quality. The<br />
torus mill 576.T3 is new to the SEAGULL® family. With its<br />
three cutting edges it is unique in the market and, as a result<br />
of its combined geometric features and cutting edge dimensions,<br />
has a lot of clearance for swarf removal and high removal<br />
rate when roughing as well as the finest contact rations<br />
when finishing.<br />
When carrying out the procedure with a copper and graphite<br />
electrode, the production time is extended to 3 hours and<br />
26 no. 3, August <strong>2022</strong>
processes<br />
57 minutes. Also here the machines from GF Machining<br />
Solutions equipped with solid carbide torus and ball end mills<br />
from the 556 series enable ZECHA tolerances of ± 0.005 mm<br />
and surface finishes of Ra 0.22 µm and VDI 7. The solid<br />
carbide torus end mills for HSC machining of non-ferrous<br />
metals are available as a short version with clearance and<br />
precision-ground, polished cutting edges and flutes. For<br />
precision in the µ-range ZECHA manufactures this tool series<br />
uncoated as standard or with a coating, optimally<br />
matched to the machining, on request.<br />
High-speed milling is another manufacturing process for<br />
injection molds. In the first two stages roughing is done with<br />
a Ø 3 mm ball mill and feed rates of 4 m/min. In contrast to<br />
machining with a larger tool, the short machining times reduce<br />
set-up times and costs, as are the number of tool places.<br />
Almost 90 % of the total machining time is spent on finishing,<br />
which places the highest demands on the tool in terms of<br />
maximum surface quality, accuracy and tool life. In the three<br />
machining stages, tolerances of ± 0,005 and surface finishes<br />
of Ra 0.1 µm and VDI 0 were achieved in 60 minutes. The<br />
high-performance end and ball mills from the PEACOCK<br />
tool series used on the Mikron MILL S 600 U reach their full<br />
potential when machining soft, hard and powder-metallurgical<br />
steels up to 70 HRC. The PEACOCK family is the innovation<br />
in the ZECHA hard milling cutter range for high-speed<br />
machining in mold making. The multi-fluted PEACOCK ball<br />
nose and torus end mills are available in different sizes: series<br />
581P ball nose mills from Ø 0.2 to 12.0 mm and series 583P<br />
and 597P torus mills from Ø 0.2 to 6.0 mm and 0.8 to 6.0 mm<br />
respectively. The new 599 series complements the PEACOCK<br />
line with immediate effect with new ball and torus mills<br />
from Ø 0.1 to 12 mm. It also includes the new 599.F4 and 599.<br />
F6 lines – special high performance end mills that stand out<br />
from the competition: the 599.F4 with a finely machined protective<br />
radius of max. 0.05 mm and the 599.F6 with a defined<br />
grinding radius, providing extra edge protection.<br />
1)<br />
SEAGULL ® Products<br />
are protected by the patent EP 2540427B1<br />
in the following countries:<br />
DE, AT, CH, LIE, CZ, FR, GB, IT, NL, PL, PT, TR.<br />
The SEAGULL ® series 576.T3 is additionally protected<br />
by the patent DE 10 2019 122 039 B3 in Germany.<br />
Copper electrode (GF Machining Solutions)<br />
The new mill design guarantees a high machining efficiency<br />
through its great performance and wear resistance for a<br />
wide range of materials, alloys and material hardnesses up<br />
to 70 HRC. A new coating technology in combination with<br />
the right solid carbide substrate, a stabilized geometry, finest<br />
micro-geometry as well as rounded shank transitions cover<br />
further applications in all shapes and component hardnesses.<br />
Even high alloy, soft materials can be dry-finished with cooling<br />
lubricant just as well as high-strength, hard materials, not<br />
only when roughing but also semi-finishing as well as fine<br />
finishing with the highest precision and component shape accuracy.<br />
Minimized friction, thanks to optimized and homogenous<br />
coating surfaces as well as excellent coating adhesion,<br />
also results in better repeatability and safety during use. The<br />
resulting potential for tool service life and surface finishes<br />
offers significant added value to the customer.<br />
The new CBN line 950 comes as a ball nose and torus end<br />
mill ranging from 0.2 to 2.0 mm. The high hardness of the<br />
substrate contributes to an increased service life of its form<br />
and dimensional accuracy. Its precise geometry results in an<br />
ideal finish on the component. Also the form contributes to<br />
the stability of the cutting edge.<br />
When complemented with digital laser technologies,<br />
aesthetic and functional texturing can be implemented both<br />
easily and reproducibly. Even complex 3D geometries, including<br />
precision parts, are precisely textured, engraved, structured,<br />
marked and labeled. Using the LASER P 400 U from<br />
Schorndorf, the last step in the aforementioned process, finishing,<br />
can be replaced with laser cutting. Compared to the<br />
milling process with integrated finishing, the production<br />
time is reduced to 37 minutes for the production of the injection<br />
mold. With the intelligent combination of milling and<br />
laser texturing, these two experts have created an efficient<br />
alternative for surface finishes of Ra 0.6 µm and VDI 16 along<br />
with the lowest tolerances of ± 0.005 mm.<br />
GF Machining Solutions and ZECHA’s product portfolios<br />
cover together all manufacturing processes, offering excellent<br />
end results. For customers this cooperation results in a<br />
wide range of possibilities, including the production of injection<br />
molds for medical technology. The subsequent supply<br />
chain efficiency enables customers to benefit from a genuine<br />
cost reduction. GF Machining Solutions and ZECHA<br />
are constantly working on optimizing EDM technologies to<br />
increase machining speeds and reduce electrode wear with<br />
highly polished surfaces of Ra 0.1 µm. As a result, they have<br />
the most economical and highest quality solution ready for<br />
every application – with specified tolerances, surface qualities<br />
and production times. They will continue to optimize their<br />
machines and tools, in order to guarantee their customers the<br />
best possible added value and support.<br />
further information: www.zecha.de // www.gfms.com<br />
no. 3, August <strong>2022</strong><br />
27
processes<br />
Seeing mobility change as an opportunity<br />
Combined drive technologies and e-mobility<br />
require a multitude of precision-ground components.<br />
The manufacturer of high-quality grinding<br />
technology, Fritz Studer AG in Thun, considers itself<br />
ideally equipped to meet this requirement with its<br />
productive machining concepts and high-quality<br />
grinding machines.<br />
Mobility change will not cause the sharp drop in production<br />
initially feared in the machining sector. The specialists<br />
at grinding machine manfuacturer STUDER in Thun<br />
are convinced of this. As Sandro Bottazzo, chief sales officer<br />
(CSO) at STUDER, points out, the range of components to be<br />
produced will slowly and continuously change over a number<br />
of years or even decades. To illustrate this, he cites the<br />
expected quantities of passenger cars sold worldwide and the<br />
shares of the respective drive technologies. “Based on various<br />
analyses, we assume that the combustion engine will<br />
con tinue to play an important part over many years and in<br />
numerous regions of the world”, states Sandro Bottazzo.<br />
“The general demand for individual mobility is continuing to<br />
increase worldwide, which offers corresponding opportunities”,<br />
says Sandro Bottazzo.<br />
Wide variety of drive technology<br />
keeps market stable<br />
In the coming decades a wide variety of drive technologies<br />
will be available in parallel. In addition to purely battery-powered<br />
electric engines, diesel engines with exhaust<br />
gas cleaning, hydrogen engines, hybrid engine technology (a<br />
combination of combustion and electric engine) and electric<br />
drives with power generated by fuel cells will still be used to<br />
power cars and trucks. Further drive technologies will even<br />
be added where possible. Meaning for production companies<br />
that there still is a great demand for precision components<br />
for the drive train. This includes shafts, axles, bushings, gear<br />
wheels and compressor wheels, camshafts and crankshafts. In<br />
addition, the autonomous vehicles currently under development<br />
will soon be produced on a larger scale. For these the<br />
automotive industry additionally requires a wide range of<br />
different precision components in large series.<br />
Complex systems increase demand<br />
Efficient drive technologies usually require very complex<br />
systems. This applies to hybrid and electric drives, for example,<br />
which recover electrical energy during regenerative braking.<br />
For machining this also means the production of an increasing<br />
number of usually very complex components. “This<br />
opens up additional opportunities. We will continue to monitor<br />
the market carefully, so that we can further develop our<br />
products accordingly”, underlines Sandro Bottazzo. The already<br />
well-known applications for innovative grinding technology<br />
include components for CVT transmissions (used<br />
primarily in hybrid drives), rotor and gear shafts for electric<br />
Exploded view of electric engine<br />
(chesky AdobeStock)<br />
engines, shafts for turbochargers, compressor shafts for fuel<br />
cells, shafts and valves for hydrogen engines, ball screws for<br />
electric steering systems as well as various precision tools<br />
for cost-effective machining of housings for electric engines.<br />
Likely there is significant growth in the latter.<br />
Productive and cost-effective<br />
with sophisticated grinding concepts<br />
As Sandro Bottazzo reports, Fritz Studer AG offers safe and<br />
reliable grinding technologies for the specified components.<br />
For example on a CVT transmission the primary and secondary<br />
shaft must be ground. This is done in a high-precision<br />
process with the shortest machining and processing<br />
time on a STUDER S41 grinding machine, in a single<br />
clamping. Even the ball track grooves in the shafts and in the<br />
holes of the sheaves can be ground in a single clamping. A<br />
vertical spindle, which is mounted on the proven Y-axis, is<br />
used on the S41 grinding machine for this purpose. A special<br />
unit, developed by STUDER, is used for high-precision<br />
grinding of the ball tracks in the sheaves. Grinding in a single<br />
clamp ing, together with fully automated processes, ensures<br />
extreme ly cost-effective production. This applies to the<br />
loading, unloading and measurement of workpieces, as well<br />
as adaptive control of grinding processes. The latter in particular<br />
contributes to the highest precision and reliability.<br />
Sandro Bottazzo stresses: “STUDER provides manufacturing<br />
companies with complete systems of matching components”.<br />
Toothed racks for electric steering systems<br />
Electric steering systems, which are specifically required for<br />
autonomously controlled vehicles, operate with precisionground<br />
threaded rods. The steering motion is driven by balls<br />
rolling inside. This “ball screw” is advantageously ground<br />
from the solid on STUDER grinding machines. Compared<br />
to other machining technologies a significantly better surface<br />
28 no. 3, August <strong>2022</strong>
processes<br />
Exploded view of conventional combustion engine<br />
(Vlad Kochelaevskiy AdobeStock)<br />
quality is achieved, with comparable machining times. The<br />
resulting advantages are reduced steering noise and a considerably<br />
longer lifetime of the steering gear. The dressing unit<br />
exclusively developed by STUDER, WireDress® (wire erosion<br />
of the profile), is used for dressing. WireDress® enables<br />
completely new possibilities when grinding with metalbonded<br />
CBN and diamond grinding wheels: not only does<br />
this electro-erosive integrated dressing technology save a huge<br />
amount of downtime, it also enables sintered metal bonds<br />
to be dressed with the highest precision in the grinding machine<br />
at full wheel speed.<br />
High-speed compressor wheels for fuel cells<br />
Fuel cells require electrically driven compressors, which<br />
operate at very high speeds. The integrated shafts and sheaves<br />
must therefore be manufactured with high precision. In addition,<br />
they comprise materials that are difficult to machine.<br />
STUDER has developed its own grinding concept for these<br />
requirements. The shafts can be pre-machined at high speed<br />
on an S41 cylindrical grinding machine by means of peel<br />
grinding. The CBN wheels are dressed with the WireDress®<br />
technology exclusively developed by STUDER. Thanks to<br />
a synchronizable tailstock, the universal cylindrical grinding<br />
machines can reliably accept components of different<br />
dimensions.<br />
Components for electrically driven turbochargers<br />
Small, powerful and extremely efficient combustion engines<br />
can only be achieved by turbochargers. But they only work<br />
with an adequate exhaust gas flow and pressure, i.e. with sufficiently<br />
high speed of the combustion engine. Only then<br />
can the compressors build up the necessary pressure to convey<br />
high quantities of combustion air into the cylinders. Insufficient<br />
air flow and pressure at low engine speed is commonly<br />
referred to as “turbo lag”. In order to prevent or reduce<br />
this, engine manufacturers are increasingly using socalled<br />
e-boosters, i.e. electrically driven charge air compressors.<br />
The integrated engine shafts can be advantageously<br />
ground on universal cylindrical grinding machines, such as<br />
a STUDER S31, for example. First the rotor shaft is ground<br />
on the diameter and at the shoulders. This requires a special<br />
clamping device to carry the workpiece. After grinding, the<br />
magnets are affixed. A titanium alloy sleeve is then pressed<br />
on by the magnets. The sleeve must now be externally ground<br />
precise to the diameter. This can be advantageously carried<br />
out on an S33 universal cylindrical grinding machine.<br />
This Tools for engine housings<br />
As Sandro Bottazzo adds, increasing electromobility<br />
means that in particular tools must be ground with<br />
high precision, in addition to the actual vehicle components.<br />
STUDER has developed a suitable concept to achieve<br />
the required accuracies; the relevant STUDER grinding<br />
machine is equipped with the LaserControl TM in-process, an<br />
optical and contact-free measuring system. The “Closed Loop<br />
Process” adaptive control controls the grinding process.<br />
further information: www.studer.com<br />
no. 3, August <strong>2022</strong><br />
29
machining center<br />
Welcome to the Machine.<br />
Farewell to the past…<br />
Footprint 1,425 x 1,875 mm. Height 2,070 mm.<br />
Free over-corner access. New operating concept. Simple<br />
programming. Unparalleled changeover times.<br />
Maximum reduction to the essentials. Namely tool<br />
grinding. This is the new Multigrind® Radical from<br />
Haas Schleifmaschinen.<br />
Multigrind ® Radical in action:<br />
big on the small scale<br />
The response to the two all-in-one tool grinding machines<br />
exhibited at GrindingHub was correspondingly great. This is<br />
not surprising, since maximum precision for rotary and plate<br />
tools is offered in the smallest possible space. This means that<br />
all customer requirements can be produced extremely flexible<br />
on just one tool grinding machine. Milling cutters, inserts,<br />
drills as required. In large quantities or as very small series<br />
from batch size 1 to 1,000.<br />
In particular, the award-winning control concept created<br />
a good mood among the trade audience. This is because the<br />
consistent decoupling of operation from the machine allows<br />
a level of freedom that has never been seen before. The Multigrind®<br />
Horizon grinding software runs in the company’s own<br />
network and is executed via laptop, tablet or cell phone. This<br />
brings unprecedented mobility to the machine operator. And<br />
automated unmanned series production becomes the production<br />
standard with this approach. Parameterization, tem-<br />
plates and ERP information form the data basis. Programming<br />
is super simple and makes very fast production changes<br />
possible. Just provide parts and start grinding. Additional<br />
performance, fast service, current updates, physical information,<br />
safety instructions, process parameters and much more<br />
can easily be retrieved from the cloud on request.<br />
Multigrind ® CB XL:<br />
complex workpieces up to 3,200 millimeters<br />
The absolute contrast to the Multigrind® Radical was the<br />
Multigrind® CB XL 3200 at the Haas Schleifmaschinen trade<br />
show booth in Stuttgart. This is because the 5-axis CNC<br />
grinding center Multigrind® CB XL sets new standards in<br />
terms of precision for the complete machining of workpieces<br />
up to 3,200 millimeters in length literally. Production in a<br />
single setup is particularly attractive for manufacturers of<br />
large tools, such as shaft parts with splines or gear cutting<br />
tools. But the oversized high-tech grinding center has also<br />
become a pacesetter in the machining of long, slender parts<br />
such as landing gear parts for aircraft, turbine components,<br />
ball screw drives, racks and guideways. Its consistent symmetrical<br />
design gives the Multigrind® CB XL the necessary<br />
stability and rigidity to meet demands in terms of precision.<br />
The Trossingen-based precision specialist demonstrated<br />
impressively at GrindingHub that the software takes manufacturers<br />
of highly complex XXL workpieces a decisive step<br />
further. Because the Multigrind® Styx visualization software<br />
enables digital pre-grinding. With visible machining heel.<br />
With all details, unevenness and transitions. Even residual<br />
ripples in the workpiece surface are displayed, for most precise<br />
adjustments and corrections and the final polish even<br />
before the first. The advantage is clear: expensive blanks and<br />
machine hours are saved.<br />
Multigrind ® Multimation:<br />
when turnkey grinding is not enough any longer<br />
The developments of recent years clearly show that the requirements<br />
in grinding are constantly increasing. However,<br />
this does not only apply to the complete machining of complex<br />
workpieces, but also to the upstream and downstream<br />
production processes. The key to success here, too: the software.<br />
The decisive factor here is the interface. In the future<br />
the Multigrind® Multimation will take over control.<br />
Production in a single setup is particularly attractive for<br />
manufacturers of large tools, such as shaft parts with<br />
splines or gear cutting tools<br />
Multimation enables manual and automatic workflows,<br />
completely customized, just as customers need it, and without<br />
any losses in process times. The interface to the ERP<br />
30 no. 3, August <strong>2022</strong>
machining center<br />
The new Multigrind® Radical revolutionises the future of tool grinding<br />
system, customized of course, just like the process. Located<br />
in the company network and always there.<br />
The advantage is obvious: It will be much easier than before,<br />
because the mapping of the setup processes was inconvenient<br />
up to now. With Multimation the entire manufacturing<br />
process can be mapped and controlled. Process components<br />
such as manual scanning, automation solution and<br />
cleaning system or labeling machine, etc. can be digitally<br />
removed and added as required. Good for productivity,<br />
individual process components can be bypassed with Multimation<br />
in the event of a malfunction and can be controlled<br />
again after the malfunction has been rectified. Intervention<br />
in the job or order lists thus becomes standard practice,<br />
resulting in a significant reduction in downtime.<br />
Hardware and software from a single source:<br />
simply unbeatable<br />
In addition to the Multigrind® Radical, the Multigrind® CB XL<br />
and Multigrind® Multimation, the precision specialists from<br />
Trossingen had their proven all-rounders and problem solvers<br />
in their luggage: the Multigrind® CU, the Multigrind® CA and<br />
the Multigrind® CB. The performance of the universal grinding<br />
centers was demonstrated by the production of rotors<br />
for pelletizing, the manufacture of inserts and skiving tools,<br />
and the resharpening and manufacture of hobs. Each workpiece<br />
in the production process is demanding in itself. With<br />
the successful interaction of hard- and software, however, it<br />
is quite simple. Because with hardware and software from<br />
the same source, there is no such thing as too complex for<br />
economical production.<br />
The 5-axis CNC grinding center Multigrind® CB XL sets new standards in terms of precision<br />
for the complete machining of workpieces up to 3,200 mm in length literally<br />
further information: www.multigrind.com<br />
no. 3, August <strong>2022</strong><br />
31
machining center<br />
Innovations in action<br />
and all-round expertise<br />
PERFORMANCE MEETS PRECISION: the new<br />
claim from the CHIRON Group is also a promise,<br />
which will be fulfilled at AMB <strong>2022</strong> with the special<br />
combination of performance and precision in products,<br />
solutions and services. For sustainably productive<br />
processes in all industries. Milling and mill-turning,<br />
additive manufacturing, automation, turnkey, digital<br />
solutions, services, refurbishment.<br />
Machine highlights live in action<br />
The CHIRON Group will showcase its expertise in the fields of<br />
milling and mill-turning with live-action demos of three innovative<br />
machining centers: the DZ 22 W five-axis efficiency<br />
booster with HSK-A 100 interface and spindle distance of<br />
600 mm for the machining of complex components for the<br />
automotive and aerospace industries. An ultra-compact plugand-play<br />
solution consisting of the Micro5 machining center<br />
with the Feed5 handling system for automated, high-precise<br />
micromachining. And the new MT 715 two+ with integrated<br />
workpiece handling for multifunctional complete machining<br />
from the bar – also in unmanned shifts.<br />
The DZ 22 W five-axis in action – a machine of the future,<br />
for complex components for e-mobility and aerospace<br />
The new MT 715 two+ with integrated workpiece handling<br />
for multifunctional complete machining from the bar<br />
Plug-and-play solution for automated micro machining:<br />
the Micro5, combined with the Feed5 handling system<br />
A special kind of cinema experience<br />
To see other highly productive machining centers in action,<br />
it is also worth visiting the «CHIRON Group cinema», which<br />
will be showing live broadcasts from Tuttlingen, Germany,<br />
twice a day. Or take a look in the interactive showroom,<br />
where you can see the STAMA 733 series for heavy mill-turning<br />
and drilling operations as well as 5-axis simultaneous<br />
machining.<br />
In an exclusive preview, visitors get a sneak peek on the<br />
latest innovation – AM coating. This industrial system applies<br />
anti-corrosion and wear-resistant coatings to brake disks, for<br />
hybrid or electric cars, for example.<br />
The CHIRON Group will be presenting tomorrow’s production,<br />
today, as digital system of the SmartLine software<br />
portfolio. How smart and intelligent are the ProtectLine and<br />
ConditionLine modules in practice, for example? The experts,<br />
together with two cooperation partners, will be demonstrating<br />
this on the DZ 22 W five-axis double spindle machining<br />
center. Visitors can then see the actual added value offered by<br />
automated tool handling with ZOLLER and coolant management<br />
with MOTOREX.<br />
AMB <strong>2022</strong>, hall 10, booth A41<br />
further information: www.chiron-group.com<br />
32 no. 3, August <strong>2022</strong>
machining center<br />
Como Industries quintuples pin gauge<br />
output with the TSCHUDIN CUBE 350<br />
TSCHUDIN covers a very wide range of machined<br />
workpieces in centerless grinding: from the smallest<br />
wires for medical technology to truck axles weighing<br />
150 kg.<br />
“It changes our way of working completely”, says Sophie<br />
Demesse, CEO of Como Industries, about the purchase of the<br />
compact, centerless TSCHUDIN CUBE 350 centerless grinding<br />
machine. Como Industries, headquartered in Courbevoie<br />
near Paris, produces pin gauges, hydraulic nuts, and other<br />
high‐accuracy pieces for well‐known customers such as<br />
Airbus, Michelin, Thales Group or Safran. The CUBE 350<br />
will be used for the production of high‐precision pin gauges.<br />
Ms. Demesse: “On the old machine, we needed five hours<br />
to manufacture 100 pin gauges with a very small diameter<br />
and a precision of 1.5 micron. With the CUBE 350, we need<br />
only one hour – a huge productivity leap!” The new grinding<br />
machine convinces not only with speed but also with optimized<br />
quality. “Before, we were not able to reach the same<br />
kind of precision when it comes to diameters between 10 and<br />
20 mm. These parts needed an extra finishing step. Thanks<br />
to the CUBE 350, this extra step is no longer needed, which<br />
boosts our efficiency”, underlines Ms. Demesse.<br />
Concentrated know-how at AMB<br />
The grinding experts of TSCHUDIN AG and the team<br />
of Como Industries will take part at AMB exposition in<br />
Stuttgart. Visitors can inquire about the successful cooperation,<br />
exchange views with Ms. Demesse, TSCHUDIN shareholder<br />
Urs Tschudin and CEO Iwan von Rotz, and of course<br />
also witness the compact, award‐winning, three‐axis CNC<br />
centerless grinding machine CUBE 350 on booth C11, hall 5.<br />
New possibilities<br />
With the upgrade of the machine park of Como Industries,<br />
Sophie Demesse sees new possibilities for future development.<br />
“Some pin gauges with larger diameters are rarely sold.<br />
In future it might make sense to produce these on demand<br />
instead of having them in stock.” Generally it is important<br />
for the company to have a stock of most of their products in<br />
the warehouse. Ms. Demesse: “If a customer calls and needs<br />
a certain product urgently the next day, we will deliver. This<br />
has been our service pledge since our founding in 1970.”<br />
The purchase of the CUBE 350 had multiple reasons, explains<br />
the CEO: “Firstly, we needed to upgrade our production<br />
because the sales are going well. Secondly, young people in<br />
this industry want to work on state‐of‐the‐art machines –<br />
without this investment it would be much more difficult to<br />
find and retain talent. It was a crucial step for us.”<br />
After first contacts Ms. Demesse travelled to EMO Milano<br />
in 2021 to meet with the TSCHUDIN team. In the discussions<br />
Urs Tschudin, shareholder of TSCHUDIN AG, gave<br />
his expert advice on how Como Industries could adapt its<br />
production and increase efficiency. From that point on, the<br />
The awardwinning<br />
centerless<br />
grinding machine<br />
TSCHUDIN CUBE 350,<br />
which has been produced for Como Industries<br />
two com panies worked closely together, including the training<br />
of Como Industries experts on the new machine in the<br />
TSCHUDIN headquarters in Grenchen, Switzerland. “For us<br />
it is important to stay one step ahead of our competition in<br />
Europe, but also in Asia. The cooperation with TSCHUDIN<br />
allows us to do so,” emphasizes Ms. Demesse. During the<br />
important phase of needs analysis, Bernard Bouillé from BB<br />
Tech also made a weighty contribution, being a distribution<br />
partner of TSCHUDIN for France.<br />
Versatile product portfolio<br />
TSCHUDIN will present its versatile product portfolio as<br />
a global technology leader in centerless grinding, at AMB<br />
Stuttgart. “In addition to the CUBE 350 described above, we<br />
will also exhibit another CUBE 350 with robot and a 400 eco-<br />
Line. Workpieces of diverse sizes can be ground on our machines:<br />
from the smallest wires for medical technology, whose<br />
shape can only be seen under a magnifying glass, to truck axles<br />
weighing 150 kg” reports Iwan von Rotz, CEO. While the<br />
CUBE 350 is designed for machining small workpieces of up<br />
to Ø 20 mm, the 400 ecoLine / proLine is ideal for machining<br />
medium‐sized workpieces of up to Ø 150 mm and the 600<br />
ecoLine / proLine can machine pieces of up to Ø 250 mm. The<br />
maximum grinding wheel width is 500 mm.<br />
The TSCHUDIN centerless cylindrical grinding machines<br />
are used in all industries where mechanical components are<br />
required with high accuracy and at economical unit costs –<br />
from injection technology, hydraulics, automotive engineering,<br />
drive technology, the bearing industry, medical technology<br />
and toolmaking to aerospace. The materials machined,<br />
such as steel, aluminum, glass, titanium, carbon, ceramics,<br />
germanium or silicon, are just as versatile as the areas of<br />
application.<br />
AMB <strong>2022</strong>, hall 5, booth C11<br />
further information: www.tschudin.swiss<br />
no. 3, August <strong>2022</strong><br />
33
machining center<br />
Planetary lapping machine for PCD and CVD<br />
Coborn’s planetary lapping<br />
machines are designed to polish<br />
the top surface of PCD discs to a<br />
flat, mirror finish<br />
The PL5 is equipped<br />
with 6 work heads as standard<br />
Coborn’s planetary lapping machines are designed<br />
to polish the top surface of PCD discs to a flat, mirror<br />
finish. They can also be used to polish CVD discs and<br />
PcBN. They consists of a number of independent work<br />
heads which hold the discs against a large, horizontally<br />
mounted planetary motion grinding wheel.<br />
tains the disc at a uniform temperature to minimise disc<br />
dishing. The PL5 is equipped with 6 work heads as standard.<br />
Each arm is fitted with a double gimbal fixture to allow the<br />
disc to self-level. The disc holders are motor-driven. The lapping<br />
pressure can be individually adjusted.<br />
The lapping or polishing of the top surface of PCD or<br />
CVD components is desirable to produce a smooth surface<br />
for chip flow and a good cutting edge for geometric<br />
integrity. It also maximises edge life, enhancing the characteristics<br />
of PCD and also minimises surface deviations over a<br />
large PCD or CVD area.<br />
The benchmark for the diamond industry<br />
The RG9A is a fully automatic, high-precision<br />
grinding machine designed to meet the sophisticated<br />
demands of toolmakers working with hard and ultra-hard<br />
materials, such as PCD, PcBN, carbides and<br />
ceramics.<br />
This versatile machine is supplied “robot ready” and the optional<br />
Stäubli 6-axis robot can be added to the RG9A to facilitate<br />
fully autonomous “lights out” production of tools.<br />
The RG9A software is user-friendly where straightforward<br />
programming blocks can be built step-by-step to produce<br />
the tool forms and geometries you need. From simple,<br />
single point shank tools to helical/radius multi-point rotary<br />
tools, the RG9A has all the capabilities needed to minimise<br />
tool production costs.<br />
The RG9A is a fully automatic, high-precision grinding machine<br />
It is impossible to use flood cooling when polishing large<br />
areas of PCD as the discs ‘aqua-plane’ on the wheel surface.<br />
Therefore, the lapping is a dry process and the wheel is internally<br />
cooled using water from an associated water chiller.<br />
Chilled water is also fed to the back of each disc. This mainfurther<br />
information: www.coborn.com<br />
34 no. 3, August <strong>2022</strong>
machining center<br />
The new productive STUDER machine S36<br />
Due to the rapid development of e-mobility and other alternative<br />
drive types, among other things, the demand for suitable<br />
grinding machines for a new variety of components in vehicle<br />
manufacture is also increasing. That is why STUDER has developed<br />
the new S36.<br />
It will be positioned between the compact S11 for small workpieces and<br />
the S22 for medium-sized workpieces. Many features of the new S36<br />
are similar to its very successful predecessor, which sold over a thousand<br />
units. New functionalities for changing requirements supplement<br />
proven concepts. “The demand for cost-effective grinding solutions for<br />
medium to large series also remains consistently high in e-mobility<br />
applications”, says project manager Martin Habegger. In addition to<br />
vehicle manufacture the new machine will also be used in the hydraulic,<br />
pump and toolmaking sectors.<br />
The S36 has a fixed grinding head with grinding wheel angles of<br />
0,° 15° or 30° available. The distance between centers is 650 mm and<br />
the maximum workpiece weight is 150 kg. Proven components have<br />
been used in the machine. These include a Granitan® machine bed and<br />
a workhead with high-precision roller bearings.<br />
Range of parts / market segment<br />
The machine concept is designed for productive external grinding of<br />
chuck and shaft components. STUDER serves many different industries<br />
with the S36. Its field of application extends from die and mold<br />
through the aerospace industry to the production of parts for the<br />
hydraulic and automotive industry.<br />
Grinding head of the new STUDER S36 production<br />
cylindrical grinding machine<br />
State-of-the-art grinding technology<br />
for optimum price/performance<br />
An outstanding feature of the new machine is its<br />
large grinding wheel, which has a Ø 610 mm and<br />
initially a maximum width of 125 mm. This makes<br />
the S36 above standard in its category. In addition,<br />
the machine comes with C.O.R.E. OS, the UNITED<br />
GRINDING Group’s smart, cross-brand operating<br />
system – including touch panel and intuitive operation.<br />
Thanks to the uniform C.O.R.E. software<br />
architecture, data exchange between the machines<br />
is easily possible. This is also possible with thirdparty<br />
systems via the integrated umati interface.<br />
This interface also provides access to the UNITED<br />
GRINDING Digital Solutions products directly<br />
at the machine and without the installation of additional<br />
hardware. C.O.R.E. creates the technical<br />
foundation not just for these and other IoT and data<br />
applications, but also for a revolutionary, standard<br />
and simple mode of operation.<br />
The newly developed SmartJet® nozzles for efficient<br />
and automatic coolant supply are fitted as standard.<br />
Thanks to these cooling is now managed by<br />
the machine control. A frequency-controlled pump<br />
and a dynamic pressure measuring unit are used<br />
as central components. These allow to precisely adjust<br />
the volume flow to suit the process – for rough<br />
grinding, fine grinding or finishing. The cooling<br />
medium is fed to the grinding wheel via manifold<br />
and flow-optimized, adjustable nozzles. “This concept<br />
guarantees precise, efficient and reproducible<br />
cooling”, emphasizes Martin Habegger. “We offer<br />
customers the S36 with all of this modern grinding<br />
technology at an excellent price/performance ratio”,<br />
says Habegger.<br />
STUDER S36 production cylindrical grinding machine<br />
further information: www.studer.com<br />
no. 3, August <strong>2022</strong><br />
35
machining center<br />
A breakthrough on superfinishing of high loaded gears<br />
Big cost savings into aerospace production<br />
High loaded gearboxes, such as reduction, propeller<br />
and helicopter gearboxes, are counted as the highest<br />
loaded gearboxes with the highest precision in design,<br />
validation and manufacturing. Many gearboxes<br />
in this application are designed as a planetary gear<br />
system that transmits the torque from the low-pressure<br />
turbine to the propeller, rotor or fan. With this<br />
gearbox design, many benefits such as fuel burn savings,<br />
engine noise reduction and engine operation cost<br />
reduction can be achieved.<br />
Besides stringent design drawing criteria, gear teeth topography<br />
(teeth flanks lay) also plays a very important role<br />
in preventing the highly loaded gears from pitting and<br />
scuffling failures. It calls for perfect gear teeth surface<br />
and can be achieved by the process introduced by OTEC<br />
Präzisionsfinish GmbH (OTEC). The gear teeth surface is not<br />
only perfectly polished, but sharp edges or burrs on the part<br />
are also being removed. With this process one also achieves<br />
different surface requirements (i.e. superfinishing, edge<br />
rounding, deburring etc.) on blades, vanes, disks, blisks,<br />
roots as well as gears.<br />
photo 1<br />
Media size in comparison to the gear geometry<br />
Stream Finishing MachineOTEC was chosen to be a partner<br />
of many well-known Aerospace OEMs and TIER 1s,<br />
because the offered processes have proven that it’s not only<br />
simple, effective and highly productive but also environmentally<br />
friendly, in line with current production requirements.<br />
OTEC’s solution proved to be economical in industrial processes<br />
as well. With less media, compound and water wastage,<br />
along with faster process time, productivity and efficiency<br />
will definitely be improved.<br />
In one particular research, a wet finishing process was conducted<br />
in OTEC’s Stream Finishing (SF) machine. High quality<br />
surface results could be achieved when the correct abrasive<br />
media, specifically chosen according to the different geometry<br />
sizes of the workpieces, was used in conjunction with<br />
the optimum machine parameter settings. With the small<br />
sized media (photo 1) used in the Stream Finishing process,<br />
small and hard to reach could easily be accessed and offering<br />
a very big advantage over the conventional methods.<br />
photo 2<br />
Low process variation<br />
achieved from OTEC’s<br />
Stream Finishing process<br />
With wet finishing,<br />
the water/compound mixture<br />
served to absorb<br />
and rinse away the particles<br />
of debris from<br />
the workpieces and the<br />
abrasive medium. This<br />
ensured that the maximum<br />
efficiency was retained<br />
throughout the<br />
entire processing cycle. OTEC’s special designed finishing<br />
process for highly loaded gears had not only got a positive<br />
impact on the roughness parameter and reduction of teeth<br />
involute curvature waviness, desirable teeth flank topography<br />
and excellence repeatability for teeth involute and teeth lead<br />
could also be achieved.<br />
Initial test pieces of a highly loaded gear were grinded by a<br />
high precision grinding machine to an ISO 1302 grade number<br />
N5 surface roughness. With OTEC’s finishing processes,<br />
a surface roughness between ISO 1302 grade N3 and N2 was<br />
achieved in a short time of only 20 – 30 minutes. Most important<br />
visual grinding lines were also removed from the part.<br />
This high accuracy surface finishing has generated a resistance<br />
against scuffing and pitting which may result in a significant<br />
increase in the lifetime of the gearbox.<br />
Photo 2 shows the calculated variation of material removal<br />
along multiple involutes for the tested workpiece. Compared<br />
to conventional methods, an incredibly low process variation<br />
of only 1 µm was achieved along the involutes with OTEC’s<br />
Stream Finishing process. This can help increase the tolerance<br />
allowanced for the initial grinding process, and scrap<br />
rate in production can also be reduced. Tighter tolerances<br />
could also be applied on the gear manufacturing drawing<br />
and thus reduce the gear weight which is also a key factor in<br />
aviation.<br />
Several well-known OEMs and TIER 1s are already partnering<br />
with OTEC, looking into the process verification<br />
and validation of the Stream Finishing solution, believing to<br />
reach another milestone in aerospace production with this<br />
partnership very soon.<br />
further information: www.otec.de<br />
36 no. 3, August <strong>2022</strong>
Highest precision with two options<br />
machining center<br />
At AMB <strong>2022</strong> Kern will present two machines –<br />
both are characterized by the highest precision on the<br />
workpiece, but based on two completely different technologies.<br />
The latest generation of the five-axis machining<br />
center Kern Micro HD and the modern laser<br />
machining center Kern Femto E3.<br />
Producing parts in serial production with a reliable process<br />
and highest accuracies in the µm-range requires machines<br />
like Kern Microtechnik GmbH provides. With the Micro HD<br />
and the Femto E3, Kern Microtechnik is showing visitors two<br />
innovative machining centers in action, which are similar in<br />
terms of color and are characterized by the highest level of<br />
precision but differ significantly in the used technology.<br />
On the Kern Micro HD Kern machines form inserts for filter<br />
housings that are milled and ground in one setting. This<br />
means that the parts are first machined and then brought<br />
to the highest surface quality at individual points using jig<br />
grinding with five-axis cycles. As a result the parts have a<br />
precision of less than 1 µm and surface qualities in the singledigit<br />
nanometer range on various contact surfaces. The usual<br />
manual polishing is no longer necessary.<br />
Also live: the new Kern Femto E3 laser machining center<br />
has proven to be the ideal manufacturing solution for the<br />
The high-precision<br />
five-axis<br />
machining center<br />
Kern Micro HD<br />
production of sintered carbide press dies and similar parts.<br />
The machine uses an ultra-short pulse laser to process hard<br />
materials with the highest dimensional accuracy of +/- 3 µm<br />
without heat input. Since the laser is not subject to wear, there<br />
are no tool costs. With surface qualities of up to Ra = 0.2 µm,<br />
the new Kern technology is highly productive and extremely<br />
stable. Compared to EDM‘ing the time of production can be<br />
cut by 75 %. The Femto E3 can also texture surfaces quickly<br />
and easily on a wide variety of materials.<br />
AMB <strong>2022</strong>, hall 7, booth B71<br />
further information: www.kern-microtechnik.com<br />
Reduced space consumption<br />
Multi-machine automation < 1.0 m<br />
Production areas are expensive, especially when<br />
they have to be air-conditioned for high-precision<br />
production applications. Therefore, production areas<br />
should primarily be used for machines. Due to the<br />
growing trend towards Industry 4.0 and automation,<br />
however, production areas for handling workpieces or<br />
tools are increasingly being lost.<br />
The new RCF30 automation from<br />
Röders is extremely space-saving and has a width of < 1.0 m<br />
In order to reduce space consumption caused by automation<br />
in production, Röders is presenting the extremely narrow linear<br />
multi-machine automation RCF30. The width, including<br />
the shelving system, is less than 1.0 m. Nevertheless, a workpiece<br />
weight of up to 30 kg can be handled. A gripper change<br />
enables the handling of different types of pallets and tools.<br />
The stiff construction makes the RCF30 very fast. The RCF30<br />
is delivered to customers in ready-made modules, avoiding<br />
lengthy, expensive installation work. A gradual expansion is<br />
possible at any time. Due to Röders' many years of experience<br />
in multi-machine automation, measuring machines, eroding<br />
machines, etc. can also be integrated.<br />
AMB <strong>2022</strong>, hall 7, booth B88<br />
further information: www.roeders.de<br />
no. 3, August <strong>2022</strong><br />
37
components<br />
Robot-assisted separation of screw and plug connections<br />
Automated disassembly of battery systems<br />
written by<br />
Thomas Götz and Andreas Gebhardt,<br />
Fraunhofer Institute for Manufacturing Engineering and Automation IPA<br />
Electromobility plays a decisive role in the design<br />
of sustainable mobility concepts, as it forms the<br />
basis for a sustainable reduction of environmentally<br />
harmful emissions. However, the transformation towards<br />
electromobility presents the German automotive<br />
industry with technical and structural challenges,<br />
which are also associated with economic and social<br />
implications. [1]<br />
The raw materials required for the production of<br />
lithium-ion batteries, such as lithium, cobalt, nickel<br />
or manganese, are proving to be particularly problematic.<br />
Their supply situation is risky due to the monopolistic<br />
market position of some production countries<br />
[2, 3]<br />
and their extraction and production are accompanied<br />
by significant ecological and social problems [4] .<br />
Against this background, a systematic recycling of battery<br />
components is imperative from an ecological, economical<br />
and strategic supply perspective. In view of the expected<br />
shortage of raw materials in the future and the simultaneous<br />
increase in demand, the recovery of technology metals<br />
by means of recycling will play a key role. This applies in particular<br />
to the materials used in electrodes. [5]<br />
Further potentials are provided by both the reprocessing<br />
and reuse of individual battery components and by the reassembly<br />
of still functioning individual parts into functional<br />
modules [6] . However, such a systematic recycling of central<br />
components requires large-scale industrial dismantling<br />
concepts with a high degree of automation [7] .<br />
dismantling<br />
level<br />
battery<br />
pack<br />
battery<br />
module<br />
detachable<br />
connection type<br />
screw connection latching welding/<br />
soldering<br />
• housing<br />
• module contacting<br />
system<br />
• battery management<br />
system<br />
• cooling system<br />
• connections<br />
• module<br />
management system<br />
• connections<br />
• battery modules<br />
• clamping elements<br />
• wiring<br />
• connections<br />
• module housing<br />
• clamping elements<br />
• wiring<br />
• connections<br />
• wiring<br />
• connections<br />
• module housing<br />
table 1<br />
Connection types of battery components [9]<br />
An important component for the fully automated dismantling<br />
of battery systems is the separation of screw and plug connections.<br />
Corresponding processes were investigated within<br />
the framework of the joint project DeMoBat – “Industrial<br />
Disassembly of Battery Modules and E-Motors”, which is the<br />
subject of this article.<br />
Structure and disassembly of battery systems<br />
Due to their high energy density, lithium-ion batteries form<br />
the basis for most modern concepts for powertrain electrification<br />
of all types of vehicles [8] .<br />
This battery technology uses lithium-ion cells that are connected<br />
in series in a module. In addition to the cells, the<br />
module contains other electronic components such as cooling<br />
modules, a cell overvoltage monitor, wiring, connections<br />
to the outside and a module management system. Several<br />
modules and other peripheral components such as clamping<br />
elements, wiring, contacting systems, external connections<br />
and the battery management system are then assembled into<br />
a battery system, which is dimensioned differently depending<br />
[9, 10]<br />
on the required performance data.<br />
The individual components are assembled into the battery<br />
system using various connection technologies, with both detachable<br />
and non-detachable techniques being employed [9] .<br />
Table 1 lists typical connection types of the individual<br />
components.<br />
For battery dismantling, the first recycling concepts for<br />
high-performance batteries of electric vehicles were developed<br />
within the research project<br />
LiBRi - “Lithium-Ion Battery<br />
undetachable<br />
• cell contact system<br />
• wiring<br />
• connections<br />
bonding<br />
• connections<br />
• cooling plates<br />
• connections<br />
Recycling Initiative”. In this context,<br />
guidelines for a recyclingcompatible<br />
battery design were<br />
also derived. Easy dismantling<br />
respectively the use of detachable<br />
connections (e.g. screw connections,<br />
latches) for cells and electronics<br />
were identified as central<br />
prerequisites for a dismantlingfriendly<br />
design. [11]<br />
In the research project Litho-<br />
Rec – “Recycling of Lithium-Ion<br />
Batteries”, the mechanical disassembly<br />
of vehicle batteries in<br />
individual components was investigated<br />
in practice. Due to<br />
38 no. 3, August <strong>2022</strong>
components<br />
the expected diversity of battery designs, the disassembly<br />
work was carried out as purely manual activities by skilled<br />
electricians with the aid of standard manual or mechanical<br />
tools. Standard tools such as screwdrivers, spanners, but also<br />
pneumatically or electrically driven screwdrivers were used<br />
for unscrewing screw connections (figure 1a). In the case of<br />
vehicle batteries that were installed on the subfloor and exposed<br />
to moisture, the housing screws could be oxi dised,<br />
so that stuck screws had to be removed destructively using<br />
chisels or angle grinders. Plug connections were opened<br />
manually (figure 1b), whereby manufacturer-spe cific plugs<br />
could usually only be opened with special tools. In case the<br />
connectors could not be opened manually, the cables were<br />
cut with cable cutters. [12]<br />
Since a higher degree of automation in the dismantling of<br />
battery systems makes an important contribution to increasing<br />
the efficiency and cost-effectiveness of the hitherto purely<br />
manual dismantling process, the first tests on the semi-automated<br />
dismantling of battery systems were carried out in the<br />
follow-up project LithiumRec II. A human- machine collaboration<br />
was investigated, in which complex disassembly activities<br />
such as loosening plug connections were carried out<br />
by a human and simple activities by a robot. Among other<br />
things, a robotic end effector was developed for automated<br />
disas sembly of screw connections, based on a cordless drill<br />
for manual handling and equipped with an additional singlefinger<br />
gripper for screw removal. [13]<br />
drilling and milling processes were investigated in detail as<br />
part of the DeMoBat project.<br />
A six-axis KUKA KR600 R2830F articulated robot with a<br />
Siemens SINUMERIK 840D controller and an HSD ES951 L<br />
1612 S high-frequency spindle used to carry out the experiments.<br />
To ensure the safety of destructive dismantling, technical<br />
requirements were therefore placed on the machining<br />
process. For example, the use of coolants and lubricants must<br />
be avoided, as moisture inside the battery can lead to short<br />
circuits. Metal chips must also be collected and removed by<br />
an appropriate extraction system, as they can lead to short<br />
circuits or other damage inside the battery.<br />
Separation of screw connections<br />
The aim of the first series of tests was to investigate robotassisted<br />
drilling and milling for the destructive separation<br />
of screw connections.<br />
For the machining tests, a simplified test carrier was<br />
developed, consisting of an aluminium tube with attached<br />
aluminium plate, both connected to each other via a steel<br />
ring with the aid of galvanised DIN 7985 pan-head screws<br />
with TORX drive of size M6 x 12 mm. The test carrier forms<br />
the components and materials of the battery housing type<br />
PHEV PB320 from Accumotive GmbH & Co.KG which was<br />
considered in the DeMoBat project. It was clamped onto the<br />
machining table by means of a three-jaw chuck.<br />
Within the scope of the test series concerning the separation<br />
of screw connections by means of robot-assisted drilling<br />
methods, the process variant of solid drilling was examined<br />
more closely, using solid carbide twist drills of the type DIN<br />
6537K of the company Gühring KG.<br />
figure 1a<br />
Manual disassembly of screw connections [14]<br />
figure 1b<br />
Manual disassembly of plug connections [15]<br />
Design and execution of experiments<br />
In order to enable automated disassembly of corroded or<br />
stuck housing screws and plug connections beyond the current<br />
state of the art, strategies for the destructive separation<br />
of screw and plug connections by means of robot-assisted<br />
As a cutting strategy, the reaming of the thread passage<br />
was considered first. A twist drill with a diameter of 6.5 mm<br />
was used to drill directly to the target depth at a cutting<br />
speed of v c = 80 m/min and a feed rate of f = 0.15 mm (“oneshot<br />
drilling” process).<br />
Since the complete screw head was stuck on the main<br />
cutting edge of the drilling tool during the drilling of the<br />
threaded passage (figure 2a) and thus the separation of<br />
a second screw connection with this tool was prevented,<br />
the drilling of the complete screw head (screw head diameter<br />
12 mm) offered itself as a second strategy, which was<br />
also investigated as a one-shot drilling process using a twist<br />
drill with a diameter of 12.5 mm. Here, a cutting speed of<br />
v c = 160 m/min and a feed rate of f = 0.25 mm were selected.<br />
When using this strategy, a screw head residue with continuously<br />
running and coherent chip elements settled on the<br />
drilling tool in the form of flow chips (figure 2b).<br />
For this reason, the alternative strategy of reaming the<br />
screw head as a drilling cycle with chip breaking (“peck<br />
drilling” process) was chosen. In this drilling cycle, drilling<br />
was carried out successively to the target depth, with a feed<br />
interruption after every 0.5 mm advance in z-direction followed<br />
by a short retraction in the opposite direction. This<br />
no. 3, August <strong>2022</strong><br />
39
components<br />
figure 2a<br />
Screw head on<br />
drilling tool Ø 6.5 mm<br />
figure 2b<br />
Screw head residue with flow chip on<br />
drilling tool Ø 12.5 mm<br />
figure 2c<br />
Screw head residue on<br />
drilling tool Ø 12.5 mm<br />
made it possible to produce fracture chips suitable for the<br />
use of an extraction system. However, in a first test run it<br />
could be observed that in about every fifth screwed connection<br />
drilled out, a screw head residue in the form of a narrow<br />
ring got caught on the main cutting edge of the drilling tool<br />
(figure 2c). This screw head residue was then carried along<br />
on the main cutting edge to the next screw head to be drilled<br />
out. This not only prevented a process-reliable separation<br />
of the following screw connection, but also resulted in the<br />
tool life limit being reached prematurely after only 32 screw<br />
connections.<br />
Since it was not possible to reliably separate the screw<br />
connections and remove the chips in the drilling processes<br />
considered, the separation of screw connections using robot-assisted<br />
milling processes was investigated in further test<br />
series. Here, circular milling was used as milling strategy.<br />
With this type of movement, the milling tool plunges into<br />
the screw head with a circular feed movement around its<br />
longitudinal axis, which enables the use of a tool-enclosing<br />
extraction system for chip collection.<br />
Four-edged solid carbide corner radius milling cutters<br />
with a diameter of 8 mm and a corner radius of 1 mm of the<br />
type NVV 0334 56 081 of the company Pokolm Frästechnik<br />
GmbH & Co. KG were used, whereby a speed of n = 4777 min -1 ,<br />
a feed rate of v f = 1433 mm/min, a cutting speed of v c = 120 m/<br />
min, a helix diameter of D h = 5 mm (drilling diameter<br />
D B = 13 mm) and an axial cutting depth per helix revolution<br />
of a* p = 0.35 mm were selected.<br />
In the milling tests it could be observed that the milling<br />
strategy allowed a safe separation of the screw connections<br />
(figure 3, a and b). An initial wear test with three test tools<br />
also revealed that under the given conditions, around 200<br />
screw connections could be reliably separated with one milling<br />
tool until the wear limit was reached.<br />
An interchangeable unit-type extraction system was developed<br />
to collect the accruing chips (figure 4, a and b). Its<br />
functionality was verified in the circular milling process application.<br />
The chips were collected via an extraction hood<br />
that could be adjusted in z-direction and to which a vacuum<br />
cleaner was connected. A brush ring was mounted around<br />
the edge of the hood to enclose the milling tool. The brush<br />
ring allowed the best possible sealing of the cutting point and<br />
avoiding collisions with the battery housing at the same time.<br />
The brush ring slowed down the ejected chips during circular<br />
milling so that they could be picked up by the air flow of the<br />
vacuum cleaner to be transported away.<br />
figure 3, a and b<br />
Separation of screw connections in the circular milling process<br />
40 no. 3, August <strong>2022</strong>
components<br />
interchangeable unit<br />
with HSK 63F mount<br />
clamping chuck<br />
connection for<br />
vacuum cleaner<br />
extraction hood<br />
brush ring<br />
cutting tool<br />
figure 4a<br />
Construction of the extraction system<br />
figure 4b<br />
Extraction system inserted in the high-frequency spindle<br />
Disconnecting plug connections<br />
Within a second series of tests, the suitability of robot-assisted<br />
drilling and milling for the destructive separation of<br />
plug connections was investigated. First, four different plug<br />
connections were selected on the basis of a plug analysis of<br />
the PHEV PB320 battery (table 2). Special care was taken to<br />
ensure that the selection covered both the largest and smallest<br />
connector in terms of dimensions, the entire material mix<br />
of all built-in connectors and all different designs.<br />
A modular clamping device was developed for the machining<br />
tests, which reproduces the geometric shapes of the<br />
respective mating connectors in an exchangeable bar. For<br />
clamping, the connectors are clicked into their mating connectors,<br />
which are then clamped in the clamping device with<br />
the help of screws. The cables crimped with the plugs are<br />
fixed by cable tensioning bars.<br />
Within the scope of the cutting tests, a double-edged<br />
HSS long-hole cutter, type 3453, with center cut and special<br />
drill face of the company Gühring KG, with a diameter of<br />
10 mm was used. The cutting strategies considered were<br />
circumferential milling in synchronisation, plunging (for<br />
plugs whose di mensions are smaller than the cutter diameter)<br />
and a combination of plunging and circumferential milling<br />
(for plugs whose dimensions are larger than the cutter diameter),<br />
where by the process parameters were adapted for each<br />
plug type (table 3).<br />
In the machining tests (figure 5), the TRU Components<br />
pre-fab braid connectors in particular presented a challenge.<br />
In some cases, for example, the flexible crimp contacts could<br />
not be completely separated by the milling cutter during the<br />
plunging strategy. A remedy was provided by circumferential<br />
milling, whereby care had to be taken to ensure that the<br />
TRU Components<br />
pre-fab braid<br />
Cimco<br />
flat connector<br />
AMP<br />
Super Seal<br />
Molex<br />
Micro-Fit<br />
table 2<br />
Selected plug connections<br />
peripheral<br />
milling<br />
plunging<br />
plunging and<br />
peripheral milling<br />
TRU Components<br />
pre-fab braid<br />
v c = 80<br />
m/min<br />
n = 2.548 min -1<br />
v f = 382<br />
mm/min<br />
n = 2.548 min -1<br />
v f = 305<br />
mm/min<br />
v c = 120<br />
Cimco<br />
flat connector<br />
m/min<br />
n = 3.822 min -1<br />
v f = 765<br />
mm/min<br />
n = 2.548 min -1<br />
v f = 485<br />
– –<br />
mm/min<br />
v c = 100<br />
AMP<br />
Super Seal<br />
m/min<br />
n = 3.185 min -1<br />
v f = 446<br />
v c = 100<br />
mm/min<br />
v c = 100<br />
Molex<br />
Micro-Fit<br />
m/min<br />
n = 3.185 min -1<br />
v f = 446<br />
– –<br />
m/min<br />
n = 3.185 min -1<br />
v f = 318<br />
mm/min<br />
v c = 80<br />
mm/min<br />
m/min<br />
n = 2.548 min -1<br />
v f = 306<br />
mm/min<br />
table 3<br />
Choice of process parameters<br />
no. 3, August <strong>2022</strong><br />
41
components<br />
cutter was guided as closely as possible to the mating<br />
connector for reliable separation.<br />
In comparison, the Cimco flat plugs which displayed<br />
a higher stability due to their high metallic<br />
content, did not pose a challenge. For this type of connector,<br />
both plunging and peripheral milling proved<br />
to be suitable cutting strategies. The retaining mating<br />
connector was either pushed away or cut by the<br />
milling tool.<br />
The AMP Super Seal as well as the Molex Micro-<br />
Fit connectors could also be separated by means<br />
of circumferential milling and a combination of a<br />
plunging movement and subsequent circumferential<br />
milling. When using the combination, it was observed<br />
that the connector broke out of the holding<br />
mating connector in some cases.<br />
As a result of the investigations, it can be stated that a reliable<br />
separation of plug connections is basically possible by using cutting<br />
processes. However, the contamination caused by the chips proves<br />
disadvantagous. In the case of connectors with a high metal con tent,<br />
the chips can lead to short circuits in the battery, which makes it necessary<br />
to collect them. In the battery under investigation, however, the<br />
required accessibility for this is not given for every plug connection.<br />
For this reason, the disconnection of cables close to the connector<br />
was investigated as an alternative. The cutting tool used was a<br />
pneumatic cutter, type AR-50, of the company Artur Martin e.K.,<br />
which uses the knife cutting<br />
method to cut the<br />
cables with the help of<br />
a wedge-shaped blade<br />
that is moved onto a flat<br />
surface. A cable cutting<br />
test rig (figure 6, a<br />
and b) was developed for<br />
the tests, allowing a defined<br />
number of cuts to<br />
cutter<br />
be made with the pneu -<br />
matic cutter.<br />
cut removal<br />
figure 5a<br />
TRU Components pre-fab braid connector –<br />
disconnection tests<br />
figure 6a<br />
Construction of the<br />
cable separation test rig<br />
cable feed<br />
cable drum<br />
housing<br />
figure 5b<br />
Cimco flat connector – disconnection tests<br />
figure 6b<br />
Cable separation<br />
test rig in use<br />
figure 5c<br />
AMP Super Seal – disconnection tests<br />
24 cables with a cross-section of 0.34 mm 2<br />
were bundled as test cables, and sheathed<br />
with the help of a fabric tape (figure 7a), which<br />
corresponds to the thickest cable bundle installed<br />
in the battery. The tests proved the<br />
suitability of the pneumatic cutters for cutting<br />
cables. Even after 2,500 cuts, the cutting<br />
edge showed no appreciable wear (figure 7b<br />
and c), while the cables were cut reliably.<br />
figure 7a<br />
Separated cables<br />
figure 5d<br />
Molex Micro-Fit – disconnection tests<br />
figure 7b and c<br />
Cutting edge after 0 cuts<br />
Cutting edge after 2,500 cuts<br />
42 no. 3, August <strong>2022</strong>
components<br />
Conclusion and outlook<br />
The recycling of battery systems will play an important role<br />
for sustainable electromobility in the future, but its economic<br />
efficiency requires a high degree of automation in the<br />
dismantling process. For this purpose, robot-assisted drilling<br />
and milling strategies were investigated in order to destructively<br />
loosen screw and plug connections. In addition, the use<br />
of pneumatic cutters for separating cables was investigated.<br />
For separating screw connections, circular milling proved<br />
to be a process-reliable method in compliance with all technical<br />
and economic requirements. An extraction system for<br />
circular milling was presented to collect the chips produced.<br />
Cutting processes also proved to be fundamentally suitable<br />
for separating plug connections. However, in some cases<br />
the necessary accessibility to the plugs in the battery is not<br />
given. As an alternative the cutting of cables close to the<br />
plugs by means of pneumatic cutters was investigated.<br />
Future research includes the cryogenic cooling of the cutting<br />
process to avoid flying sparks and monitoring the extraction<br />
process of the chips. A robot-guided cable cutting<br />
unit (consisting of a gripper and pneumatic cutters) will also<br />
be developed and tested.<br />
Acknowledgements<br />
The project DeMoBat – “Industrial dismantling of battery<br />
modules and e-motors to secure economically strategic<br />
raw materials for e-mobility”, on which the present investigations<br />
are based, is funded by the Baden-Württemberg<br />
Ministry for the Environment, Climate and Energy Management<br />
(UM BW) and supervised by the Karlsruhe Project<br />
Management Agency (PTKA). The authors would like to<br />
thank the UM BW for the funding granted as well as the<br />
PTKA and all project partners involved for their support.<br />
Special thanks go to Andre Mildner, Konrad Kollotzek and<br />
Lukas Zimmermann for the support provided as part of<br />
their respective thesises.<br />
Literature<br />
[1]<br />
Luhn, M (2021)<br />
Transformation zur Elektromobilität: eine<br />
empirische Analyse zur Identifizierung der relevanten<br />
Einflussfaktoren und Modellierung der Transformationsfähigkeit<br />
von Automobilzulieferern in Deutschland<br />
DuEPublico: Duisburg-Essen Publications online,<br />
University of Duisburg-Essen, Germany<br />
[2]<br />
Reuter, B.; Hendrich, A. (2020)<br />
Verfügbarkeit kritischer Rohstoffe für Elektrofahrzeuge<br />
ATZ – Automobiltechnische Zeitschrift 122/4, page 54 - 57<br />
[3]<br />
Backhaus, R. (2021)<br />
Batterierohstoffe – Woher und wohin?<br />
ATZ – Automobiltechnische Zeitschrift 123/9, page 8 - 13<br />
[4]<br />
Köllner, C. (2021)<br />
Öko-Probleme bei den Batterie-Rohstoffen<br />
Lithium und Graphit<br />
internet: https://www.springerprofessional.de/batterie/<br />
ressourceneinsatz/oeko-probleme-bei-den-batterierohstoffen-lithium-und-graphit/18790148<br />
[5]<br />
Berger, C. (2021)<br />
Batterie-Recycling ist entscheidendes Zukunftsthema<br />
internet: https://www.springerprofessional.de/batterie/<br />
elektrofahrzeuge/batterie-recycling-ist-entscheidendeszukunftsthema/19241690<br />
[6]<br />
Buchert, M.; Sutter, J. (2020)<br />
Stand und Perspektiven des Recyclings von<br />
Lithium-IonenBatterien aus der Elektromobilität<br />
Synthesepapier erstellt im Rahmen des vom Bundesministerium<br />
für Umwelt, Naturschutz und nukleare Sicherheit<br />
geförderten Verbundvorhabens MERCATOR “Material Effizientes<br />
Recycling für die Circular Economy von Automobilspeichern<br />
durch Technologie ohne Reststoffe”, Darmstadt<br />
[7]<br />
Köllner, C. (2019)<br />
Ist Second Life besser als direktes Akku-Recycling?<br />
internet: https://www.springerprofessional.de/batterie/<br />
recycling/ist-second-life-besser-als-direktes-akkurecycling-/16512034<br />
8]<br />
Tschöke, H. (2015)<br />
Die Elektrifizierung des Antriebsstrangs<br />
Wiesbaden: Springer Fachmedien Wiesbaden<br />
[9]<br />
Weyrich, M.; Natkunarajah, N. (2013)<br />
Konzeption einer automatischen Demontageanlage<br />
für Lithium-Ionen-Batterien<br />
in: VDI Automatisierungskongress<br />
[10]<br />
Kampker, A.; Heimes, H. H.; Deutskens, C. et al. (2015)<br />
Montageprozess eines Batteriepacks<br />
[11]<br />
Treffer, F. (2011)<br />
Abschlussbericht zum Verbundvorhaben Entwicklung<br />
eines realisierbaren Recyclingkonzeptes für die<br />
Hochleistungsbatterien zukünftiger Elektrofahrzeuge<br />
Lithium-Ionen Batterierecycling Initiative – LiBRi, im<br />
Rahmen des FuE-Programms “Förderung von Forschung<br />
und Entwicklung im Bereich der Elektromobilität”<br />
[12]<br />
Kwade, A.; Bärwaldt, G. (2012)<br />
Recycling von Lithium-Ionen-Batterien<br />
Abschlussbericht des Verbundprojektes, Braunschweig<br />
[13]<br />
Kwade, A.; Diekmann, J.; Hanisch, C. et al. (2016)<br />
Recycling von Lithium-Ionen-Batterien<br />
Abschlussbericht der TU Braunschweig, Braunschweig<br />
[14]<br />
Schaal, S. (access August 2, <strong>2022</strong>)<br />
Volkswagen Group Components nimmt<br />
Pilot-Recyclinganlage in Betrieb<br />
internet: https://www.electrive.net/2021/01/29/<br />
volkswagen-group-components-nimmt-pilotrecyclinganlage-in-betrieb/<br />
[15]<br />
Gerbers, R.; Mücke, M.; Dietrich, F. et al. (2016)<br />
Simplifying Robot Tools by Taking Advantage of<br />
Sensor Integration in Human Collaboration Robots<br />
Procedia CIRP 44, page 287 - 292<br />
further information: www.ipa.fraunhofer.de<br />
no. 3, August <strong>2022</strong><br />
43
components<br />
Analyzing and optimizing cleaning processes<br />
Cleaning processes often offer considerable potential<br />
for improvement when it comes to making parts<br />
cleaning operations more reliable, economical and sustainable.<br />
The first step is to make a systematic process analysis that<br />
also takes a close look at upstream and downstream production<br />
steps. To ensure the quality of subsequent process steps,<br />
avoid rejects and guarantee the functionality of the end product,<br />
consistent parts cleanliness is an essential quality criterion.<br />
Ever-stricter or even modified cleanliness specifications<br />
must be met. In addition demands on the speed, costeffectiveness<br />
and sustainability of the cleaning process are<br />
constantly rising. However, how well, fast and efficiently the<br />
cleaning work is carried out depends not only on the equipment,<br />
the process technology and the medium used, but also<br />
on factors relating to the cleaning process itself.<br />
Systematic process analysis –<br />
looking at the big picture<br />
So what do you do if suddenly stained parts come out of the<br />
system, if specifications for particulate or thin-film cleanliness<br />
are no longer met, the cleaned parts arrive corroded<br />
at the customer’s, or cleaning is too slow/too cost-intensive?<br />
In these and other cases a systematic process analysis<br />
carried out by – for example – the Ecoclean Academy at<br />
Ecoclean GmbH can pinpoint the cause of the problems. The<br />
cleaning experts not only focus on the actual cleaning process<br />
and equipment, but also assess the overall manufacturing<br />
environment. The smallest change to the part, part spectrum<br />
or material, type of contamination, or modifications<br />
to upstream or downstream processes is enough to seriously<br />
impair cleaning results.<br />
Stains and thin-film residues on parts<br />
According to the cleaning experts a poor cleaning result or<br />
one that does not meet new higher requirements is a “classic”<br />
reason for carrying out a process analysis. The first step is to<br />
identify the exact problem – are thin-film cleanliness specifications<br />
not being fulfilled or are there stains on the parts?<br />
If staining is the problem, one of the questions to be asked<br />
is whether the quantity and composition of the contaminants<br />
(processing media and other substances) have changed or<br />
whether the constituents and concentration of the cleaning<br />
medium are still appropriate. Other factors, such as rinsing<br />
water quality, bath treatment, process technology and process<br />
sequence, as well as the drying step, are also closely examined.<br />
These are further influencing variables playing a role if<br />
thin-film cleanliness results are unsatisfactory.<br />
Inability to meet particulate<br />
cleanliness requirements<br />
If the cleanliness analysis after the cleaning cycle shows that<br />
too many or too large particles are still adhering to the parts,<br />
Regular inspection and maintenance of machine components<br />
such as filters are essential factors when it comes to meeting<br />
particulate cleanliness requirements in a consistent and<br />
economical manner<br />
this may also be due to the cleaning program and process<br />
sequence used. Possible causes include residual particles in<br />
the working chamber or on the part carriers, an unsuitable<br />
filtration system or a clogged filter. Sometimes it is the wrong<br />
choice of cleaning containers, such as crates made of perforated<br />
galvanized sheet metal, which hinders the efficient and<br />
reliable detachment and removal of the particles. This type of<br />
crate blocks ultrasonic waves and prevents them from developing<br />
their full effect on the wash load. Likewise, the spray<br />
pressure does not reach the inside of the perforated crates.<br />
Compared to baskets made of round wire, a further problem<br />
is that the cleaning medium does not drip off these crates<br />
as effectively. This may result in the unwanted transfer of<br />
contaminants and/or cleaning chemicals. In any case much<br />
longer and thus more energy-intensive drying processes are<br />
required.<br />
A further cause of a failed cleanliness inspection is often<br />
burrs that are still attached to the parts, which detach when<br />
the parts are handled during the residual contamination<br />
check and then show up on the particle filter. If these particles<br />
are examined under a microscope, it can be determined<br />
whether they are chips or burrs. If the latter is the case, upstream<br />
processes must be evaluated to find out where the<br />
burrs occur and how their formation can be avoided. Particulate<br />
cleanliness can also be impaired by magnetism that is<br />
“bought in” with raw materials or arises during the manufacturing<br />
process. Magnetism binds chips to the parts and hinders<br />
or prevents their removal during the cleaning process.<br />
44 no. 3, August <strong>2022</strong>
components<br />
In many cases, retrofitting/upgrading the cleaning system with process technology, for example with ultrasonics,<br />
makes it possible to consistently achieve the required results and to shorten cleaning times<br />
Handling parts after cleaning<br />
When the parts come out of the machine with the required<br />
level of cleanliness the cleaning process is not over yet. To<br />
prevent recontamination or corrosion, which can occur even<br />
with preserved or passivated parts, it is important to look at<br />
the handling of the parts after the cleaning step. The following<br />
questions need to be answered: Where, how and for how<br />
long are the parts stored? How are they transported to the<br />
next processing step? What kind of packaging is required?<br />
Additionnally high cleanliness requirements for processes often<br />
need to be performed in a clean environment or cleanroom,<br />
such as internal transport, assembly or packaging.<br />
Updating the cleaning process<br />
Besides cleaning problems, modified cleaning programs can<br />
be a further reason for carrying out a process analysis. The<br />
aim is generally to shorten process times or enhance the<br />
cleaning result. The analysis always starts by documenting<br />
the actual state, including verifying the process parameters,<br />
process sequence and process times. Based on the analysis results,<br />
potential for improvement can be identified and appropriate<br />
measures can be defined. These may include modernizing<br />
the system, such as by retrofitting or upgrading ultrasonic<br />
equipment.<br />
Qualified personnel<br />
It is essential that the parts cleaning staff are involved in the<br />
process analysis and optimization measures. Raising staff<br />
awareness about cleanliness, as well as about the capabili-<br />
Thanks to<br />
systematic<br />
process analysis<br />
sources of<br />
error and<br />
potential for<br />
improvement<br />
can quickly be<br />
identified<br />
ties of the cleaning technology and the impact of parameter<br />
settings on the cleaning result, is a key factor. If there is<br />
a change of personnel, it is also important that knowledge<br />
of how the cleaning system works and how, for example,<br />
bath treatment measures or regular maintenance work<br />
on the cleaning system are carried out is passed on. Otherwise,<br />
problems that had been eliminated in the past may<br />
occur again. Investing in the training and continuing<br />
education of cleaning staff is therefore a cornerstone in or -<br />
der to achieve reliable cleanliness requirements in an economical<br />
and sustainable manner. The Ecoclean Academy<br />
therefore also combines process analyses with classic training<br />
courses.<br />
further information: www.ecoclean-group.net<br />
no. 3, August <strong>2022</strong><br />
45
components<br />
100 % tool management<br />
New releases available<br />
Beyond a big face-lift, TDM Release<br />
2023 allows users to synchronize their<br />
databases and achieve optimized range<br />
calculation easier. In TDM Global Line,<br />
the operational applications in the tool<br />
room and the handling of the tool lifecycle<br />
has also been developed further.<br />
Smaller machining companies which<br />
are looking for a simple, cost-effective<br />
entry-level solution can find out about<br />
the cloud-based TDM Cloud Essentials<br />
software line.<br />
TDM Global Line 2023 offers, among other things,<br />
further developments in the Tool Room<br />
TDM 2023 with a big face-lift facilitates the synchronization of databases<br />
TDM Systems is presenting their products and services under this<br />
headline at the AMB <strong>2022</strong>. In addition to the new main releases from<br />
TDM Global Line and TDM, the provider of tool management solutions<br />
is presenting their new services for processing tool data and demonstrating<br />
the opportunities and benefits of connecting to machine tools.<br />
“Companies that do not digitalize lose their competitiveness,” states the CEO of<br />
TDM Systems, Jean-Paul Seuren, with certainty. The company has offered software<br />
solutions for the efficient management of tool data and tools for over 30<br />
years. “The core competence of TDM Systems is offering machining companies<br />
a highly integrable solution. This supports the entire process chain for the chipmaking<br />
production and ensures that the tools always remain available.”<br />
New data services for<br />
users and tool manufacturers<br />
TDM Systems now offers new data<br />
services for both users and tool manufacturers.<br />
“We have a dedicated data<br />
team who has excellent expertise and<br />
takes on the task of data creation for<br />
customers,” explains Seuren. “Furthermore<br />
we also offer tool manufacturers<br />
the user-optimized digitalization of<br />
their data catalogs."<br />
Data transfer to the machine<br />
And there is something else that will<br />
excite visitors at the TDM booth,<br />
according to Seuren: “We will demonstrate<br />
how the machine down times in<br />
production can be minimized.” Users<br />
can use different communication options<br />
with the production machines to<br />
implement an automated transfer of<br />
tool and order data directly to the machine<br />
control system. This means that<br />
the required tool data can be transferred<br />
without any errors and, by monitoring<br />
the tool life, tools can be retrofitted<br />
in a timely manner.<br />
TDM tool circulation<br />
at DMG Mori<br />
Together with the machine tool manufacturer<br />
DMG Mori, TDM Systems is<br />
also presenting a live showcase with<br />
integrated tool circulation. This also<br />
includes partner systems, such as<br />
Siemens NX, Esprit, Vericut and Haimer<br />
presetting systems.<br />
AMB <strong>2022</strong>, hall 2, booth B43<br />
information: www.tdmsystems.com<br />
46 no. 3, August <strong>2022</strong>
components<br />
Expanding the field of view in micromachining<br />
Aerotech, the specialist for motion control and positioning<br />
systems, will be exhibiting at Micronora <strong>2022</strong><br />
in Besançon September 27 - 30, hall C booth 306. The<br />
innovative IFOV function for expanding the field of<br />
view during laser scanning will be demonstrated, as<br />
well as the latest features of the Automation1 control<br />
platform.<br />
Micronora is one of Europe’s leading events for microtechnology,<br />
micronanotechnology and precision manufacturing.<br />
This year the fair will be also held “hybrid” for the first<br />
time: on the digital platform “e.micronora”, both real and<br />
virtual visits can be planned, appointments and participation<br />
in accompanying specialist conferences and lectures<br />
be made. “For Aerotech Micronora, as a globally renowned<br />
niche trade fair, is an excellent address to demonstrate our indepth<br />
know-how in microproduction and nanopositioning”,<br />
confirms Simon Smith, European director of Aerotech. “With<br />
our focus topics laser and measurement technology as well as<br />
additive manufacturing support around high-precision positioning<br />
systems in the nanometre range, we find the right<br />
trade audience at Micronora.”<br />
Multi-scanner systems enable complex, large-area and highly<br />
dynamic laser processing between several axes<br />
Laser scanning without stitching<br />
Micronora shows micro actuators, micro sensors and micro<br />
dispays. To improve structural accuracy error-free in “traditional”<br />
stitching, for example, Aerotech’s proven Infinite<br />
Field of View (IFOV) feature is a unique and industry-leading<br />
solution for synchronising linear or rotary servo axes with laser<br />
scanners. IFOV significantly improves throughput, eliminates<br />
seam errors and part quality issues caused by overlapping<br />
and mismatched laser processing. By combining the<br />
highly dynamic capabilities of galvo scanners with the travel<br />
range of servo stages, parts significantly larger than the traditional<br />
field of view of a scanner can be machined continuously<br />
without having to join individual work areas. One example<br />
of this is the production of OLED displays. A big challenge is<br />
cutting out the individual displays from a much larger substrate.<br />
Laser cutting has proven itself for this process step of<br />
micromachining. Multi-scanner systems with IFOV controllers<br />
from Aerotech enable complex, large-area and highly dynamic<br />
laser processing between multiple axes and field-ofview<br />
expansion without the familiar stitching.<br />
further information: www.aerotech.com<br />
Reliable cable guiding on industrial robots<br />
By using the ROBOTRAX cable carrier system in<br />
combination with the innovative PBU pull back unit<br />
from TSUBAKI KABELSCHLEPP, automation expert<br />
KEBA Industrial Automation was able to set up a realistic<br />
technology demonstrator. Reliable cable guiding<br />
was a key element of success.<br />
The international automation expert for machine-integrated<br />
robots, KEBA Industrial Automation, uses its latest demonstrator<br />
to highlight the opportunities of creating a digital<br />
twin of an industrial robot. To illustrate the corresponding<br />
applications, an industrial robot with a versatile tool simulator<br />
was set up. Just as in practical application, a multicore cable<br />
had to move along with this tool simulator, reliably and<br />
safely guided in the robot work envelope even at the highest<br />
travel speeds. TSUBAKI KABELSCHLEPP provided support<br />
with the ROBOTRAX cable carrier, which is in three dimensions<br />
flexible and was optimized for use on industrial robots.<br />
With the PBU pull back unit reliable cable guiding in different<br />
robot positions at high speeds was achieved. The Austrian<br />
distributor for TSUBAKI KABELSCHLEPP provided support<br />
for the practical optimization.<br />
“The cable carrier system impressed us with its easy<br />
installation and versatile fastening options,” explains<br />
Michael Garstenauer, product manager robotics at KEBA. “In<br />
combination with the pull back unit, reliable pretension is<br />
ensured along the complete demonstration paths.” The<br />
dreaded knocking of the energy chain against the robot is<br />
prevented even at the highest speeds while retaining full freedom<br />
of movement. The result is a thoroughly reliable overall<br />
solution that is suitable for long-term use.<br />
further information: www.kabelschlepp.de<br />
no. 3, August <strong>2022</strong><br />
47
components<br />
Efficient automation with robotics,<br />
software and storage system<br />
The system manufacturer KELCH GmbH will be<br />
showcasing the next Industry 4.0-compliant development<br />
stage at this year’s AMB: an efficient automation<br />
concept for machining companies. The total modular<br />
concept is a joint offering with Bachmann Engineering<br />
AG, experts in turnkey robotic cells and automation<br />
solutions, and MySolutions AG, the all-in-one provider<br />
for smart factory automation.<br />
Live presentations will be held showing the entire tool cycle<br />
with the KELCH KENOVA set line V3 and V9 tool presetters<br />
and robotic assistance in a modern smart factory. Collaboratively,<br />
the partners will be supplying complete solutions<br />
worldwide to fully integrate third-party systems on a hardware<br />
and software level.<br />
Efficient automation, flexibly tailored to customers’ needs,<br />
is the aim of the total concept being presented at the AMB.<br />
The concept can also be applied to existing machines and,<br />
being modular, can be introduced into customers’ companies<br />
in small steps, depending on their budget and situation.<br />
“KELCH Industrial Line and Premium Line tool presetters<br />
can be fully integrated into the hardware and software<br />
of automation processes. We will be showcasing this with the<br />
example of a V3 and a V9-S model at the trade fair,” reports<br />
Viktor Grauer, deputy managing director and head of product<br />
and innovation management at KELCH. Automation options<br />
range from tool cleaning, shrinking, assembly to specification<br />
dimensions, balancing and measuring to storage. The<br />
available safety features provide for continuous monitoring<br />
of all processes: from automatic detection of the spindle insert<br />
during automatic change, control of all critical statuses<br />
and media (air, electricity, temperature etc.) to remote monitoring<br />
by IoT. Extended automation is provided for by the<br />
integration of solutions supplied by the cooperation partners<br />
MySolutions and Bachmann Engineering, who along with<br />
KELCH will have their own consultants at AMB.<br />
Optimised use of resources<br />
“As MySolutions AG has been the exclusive sales partner for<br />
KELCH products in Switzerland since 2020, we will be showcasing<br />
our seamless integration with KELCH KENOVA tool<br />
presetters at AMB – including our 2D.ID identification solution.<br />
Our innovative ‘THE BOX’ storage system can also be<br />
integrated, along with our mobile and stationary MyXPert<br />
software products,” explains Paul Gossens, managing director<br />
of MySolutions AG. Visitors of AMB will also learn how<br />
the MyXPert production manager can assist work scheduling<br />
personnel to technically and visually merge all administrative<br />
data and information (including orders/workflows, resources,<br />
NC programs, tool correction data, tools, test and<br />
measuring equipment). This also applies to data from existing<br />
third-party systems, such as ERP/PPS, MES, PLM etc.<br />
THE BOX, the innovative MySolutions storage system<br />
optimises the use of floor space in the warehouse<br />
In conjunction with the MyXPert terminal, a versatile and<br />
modular shop floor management system, product personnel<br />
will receive all production-relevant information on all operating<br />
resources (products, tools, equipment, measuring/<br />
test equipment etc.) on a central user interface directly at the<br />
machine. Seamless integration to external systems (such<br />
as CNC machines, manual and automated storage systems<br />
etc.) is possible using the MyXPert framework, regardless of<br />
whether data and information is merely to be visualised or<br />
reported directly back to external third-party systems. The<br />
result: optimised use of all resources in the production process,<br />
including tool set-up and tool preparation. The modular<br />
MySolutions automated warehouse management concept<br />
provides a valuable addition to automated production:<br />
48 no. 3, August <strong>2022</strong>
components<br />
Controller tool presetting including robot from a tablet:<br />
this is now possible with the KENOVA set line V3 CNC and<br />
V956-S in conjunction with the MySolutions MyXPert<br />
tool manager<br />
Automated equipping and changing of tools on KELCH tool<br />
presetters: shown here with a UR10e robot including gripper<br />
on the Bachmann Movable Base<br />
the innovative vertical storage system, known as THE BOX,<br />
is designed for the weight-independent storage of small and<br />
mid-sized products, and optimises the use of floor space in<br />
the storage area. The concept can be extended vertically and<br />
hori zontally any time through horizontally and vertically<br />
stackable elements. Unlike conventional cabinet and drawer<br />
systems, THE BOX enables products to be removed at an<br />
ergonomic height throughout.<br />
Mobile platform:<br />
Bachmann Movable Base with collaborative robot<br />
Bachmann Engineering AG, another KELCH cooperation<br />
partner, will be presenting an additional automation system<br />
at the KELCH booth on AMB, which is specifically designed<br />
for mid-sized to larger companies with their own in-house<br />
CNC machining capability.<br />
The base is formed by the Bachmann Movable Base BMB,<br />
a mobile platform specifically for collaborative robots, which<br />
are flexibly equipped and can be moved to wherever they are<br />
needed. Each platform is equipped with a UR10e robot including<br />
gripper for tool holders positioned directly downstream<br />
of the KENOVA set line V3 or V9 tool presetter to<br />
equip and change tools on the KELCH tool presetters. Live<br />
presentations at the booth will be demonstrating its use<br />
in tool measurement and tool presetting together with the<br />
automated KELCH tool presetters. The system can also be<br />
used in smaller production units, as the Bachmann Moving<br />
Device with a footprint of less then 0.5 m 2 can be simply and<br />
quickly assigned to any production and assembly process. It<br />
includes interfaces to UR3/UR5 and UR10 robots, with other<br />
robots also being possible as required.“The Movable Base and<br />
corresponding robots open up a wide range of uses to companies.<br />
For instance, the automation system might be equipping<br />
a CNC machine during the day, and still preparing the<br />
tools for the next day in the evening,” underlines Marc Strub,<br />
managing director of Bachmann Engineering AG.<br />
Automated complete tool measurement<br />
The entire tool presetting process including robots can be<br />
controlled from a tablet and with all common operating<br />
systems by combining the KENOVA set line V3 CNC and<br />
V956-S with the MySolutions MyXPert tool manager. The<br />
Bachmann Engineering AG UR10e cobot supports the tool<br />
measurement process through automatic loading and unloading<br />
processes – either controlled by a tablet or by visual<br />
detection. The 2D.ID code is scanned and the measuring<br />
specification is transmitted to the system. The measuring<br />
results achieved are saved and the tracking data is<br />
monitored by the MyXPert Tool Manager. “The automated<br />
production solutions showcased on the KELCH stand<br />
at the AMB make the use of individual hardware and software<br />
systems more efficient, but can also help to com -<br />
pen sate for personnel shortages,” continues KELCH manager<br />
Viktor Grauer.<br />
AMB <strong>2022</strong>, hall 1, booth F70<br />
further information: www.kelch.de<br />
no. 3, August <strong>2022</strong><br />
49
fairs in alphabetical order<br />
AMB Stuttgart, Germany<br />
(September 13-17, <strong>2022</strong>)<br />
bauma Shanghai, China<br />
(November 22-25, <strong>2022</strong>)<br />
CIMT Beijing, China<br />
(April 10-15, 2023)<br />
DEBURRING Karlsruhe, Germany<br />
EXPO (October 10-12, 2023)<br />
EMO Hanover, Germany<br />
(September 18-23, 2023)<br />
EPHJ Geneva, Switzerland<br />
(June 6-9, 2023)<br />
FEIMEC São Paulo, Brazil<br />
(May 9-13, 2023)<br />
GrindingHub Stuttgart, Germany<br />
(May 14-17, 2024)<br />
GrindTec Leipzig, Germany<br />
(March 7-10, 2023)<br />
Hannover fair Hanover, Germany<br />
(April 17-21, 2023)<br />
IMT Brno, Czech Republic<br />
(October 3-7, <strong>2022</strong>)<br />
IMTS Chicago, USA<br />
(September 12-17, <strong>2022</strong>)<br />
JIMTOF Tokyo, Japan<br />
(November 8-13, <strong>2022</strong>)<br />
LIGNA Hanover, Germany<br />
(May 15-19, 2023)<br />
MACH-TECH and Budapest, Hungary<br />
INDUSTRY DAYS (May 16-19, 2023)<br />
METALEX Bangkok, Thailand<br />
(November 16-19, <strong>2022</strong>)<br />
MOULDING Stuttgart, Germany<br />
EXPO (June 13-16, 2023)<br />
MSV Brno, Czech Republic<br />
(October 3-7, <strong>2022</strong>)<br />
SIAMS Moutier, Switzerland<br />
(April 16-19, 2024)<br />
sps Nuremberg, Germany<br />
sps on air digital (November 8-10, <strong>2022</strong>)<br />
TIMTOS Taipei, Taiwan<br />
(March 6-11, 2023)<br />
current status<br />
<strong>2022</strong><br />
<strong>2022</strong><br />
2023<br />
2023<br />
2023<br />
2023<br />
2023<br />
2024<br />
2023<br />
2023<br />
<strong>2022</strong><br />
<strong>2022</strong><br />
<strong>2022</strong><br />
2023<br />
2023<br />
<strong>2022</strong><br />
2023<br />
<strong>2022</strong><br />
2024<br />
<strong>2022</strong><br />
2023<br />
trade fair dates as by beginning of August <strong>2022</strong>; we are not responsible for reliability of these dates<br />
50 no. 3, August <strong>2022</strong>
impressum<br />
ISSN 2628-5444<br />
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editorial<br />
Aerotech, Inc. .......................47<br />
AMB Messe Stuttgart. ................25<br />
ANCA Pty Ltd. ......................10<br />
CHIRON Group .....................32<br />
Coborn Engineering Co Ltd ...........34<br />
Ecoclean GmbH .................... 44<br />
EMUGE-Werk GmbH & Co. KG .......16<br />
Fraunhofer Institute for<br />
Manufacturing Engineerig and<br />
Automation IPA ...................38<br />
Fritz Studer AG ................. 28, 35<br />
Gleason Corporation ................19<br />
Haas Schleifmaschinen GmbH ........30<br />
Hartmetall-Werkzeugfabrik<br />
Paul Horn GmbH ............ 6, 13, 15<br />
KELCH GmbH ..................... 48<br />
Kern Microtechnik GmbH ............37<br />
advertising index<br />
company finder<br />
Lach Diamant<br />
Jakob Lach GmbH & Co. KG ..14 , 18, 20<br />
Leuco Ledermann GmbH & Co. KG ....17<br />
LMT Tools Group ...................19<br />
NEURA Robotics ....................19<br />
OTEC Präzisionsfinish GmbH ........36<br />
Platinum Tooling Technologies, Inc. ...14<br />
Röders GmbH .......................37<br />
Scansonic MI GmbH .................23<br />
TDM Systems GmbH ............... 46<br />
TIMTOS .......................... 24<br />
TITANS of CNC ................... 24<br />
Tschudin AG .................... 23, 33<br />
TSUBAKI KABELSCHLEPP .........47<br />
UNITED GRINDING Group .........22<br />
Yamawa Europe Spa .................12<br />
ZECHA ........................ 16, 26<br />
CERATIZIT Deutschland GmbH ...................................... back cover<br />
Haas Schleifmaschinen GmbH ...........................................page. 9<br />
Jimmore Intenational Corporation .......................................page.11<br />
Lach Diamant Jakob Lach GmbH & Co. KG .......................inside front cover<br />
Landesmesse Stuttgart GmbH ............................................page 15<br />
Hartmetall-Werkzeugfabrik Paul Horn GmbH ..........................front cover<br />
Reishauer AG ..........................................................page 5<br />
ZECHA Hartmetall-Werkzeugfabrik ......................................page 13<br />
no. 3, August <strong>2022</strong><br />
51
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