hpt 2023 #3

ISSN 2628-5444
high precision tooling
Machine Tools, PCD, PVD, CVD, CBN, Hard Metal 2023 –3
■ Portfolio for automated electrode production ■ Using high performance, high-end tools in mould making ■
■ Lightweight damper system for use in lightweight structures ■ What to expect at EMO ■

CUSTOMER ORIENTED REVOLUTION
VISIT US AT THE EMO
IN HANNOVER
18. – 23.09.2023
EMO
18. – 23.09.23
Hall 11
Booth E34
OUR MACHINES ON DISPLAY
favorit – The price hit for a large range of applications
S33 with uniLoad – The reasonably priced for individual requirements
S31 with new loading system –The versatile for big tasks
S100 – The perfect machine for the entry-level segment
S131 with roboLoad – The universal machine for a wide range of internal
grinding applications
studer.com/emo
The Art of Grinding.
A member of the UNITED GRINDING Group

editorial
Eric Schäfer
editor-in-chief
The full range…
…awaits visitors to the world’s leading trade fair for production
technology in Hanover. EMO HANNOVER 2023 scores with
a unique range of technology that covers the entire spectrum
of production technology. From machining centers and lathes
to cutting tools and clamping devices to measuring equipment
and control systems. The show covers all the major topics in the
industrial value chain, presenting current state of the art and
possible future scenarios for the coming developments.
It is important for visitors to filter through the innovations and
new developments that can be used to advance their own
manufacturing and production. This issue of hp tooling, with its
extensive EMO section, aims to help. Readers of this issue will also
find in-depth information on the three major trend topics at the
show – digitalization, additive manufacturing and sustainability
in production.
One more word on sustainability: it not only affects production
itself, but starts with the tool used, the coolant used and through
every individual step. Circular economy is the key word. It
can extend the life cycle of products and raw materials to the
maximum, for example by sharing, leasing, recycling, repairing
and refurbishing. When it comes to optimizing production
processes, digitalization – also in combination with artificial
intelligence – leads to higher quality and more cost-effective
products.
Irrespective of the current topics, EMO will show whether the full
range will lead to full order books. Experts are expecting the first
indications of whether or not the currently gloomy global business
outlook in the machine and tool building sector will recover in the
foreseeable future.
Hall 11
Booth C19
Functionally
perfect surfaces
Visit us in hall 11, booth C19 to experience
innovative technologies, solutions and trends around
surface finishing life. Meet our experts and let us
work together on your tailor-made solution.
Be there! We are looking forward to your visit.
Superfinishing
Flat Finishing
Fine Grinding
Double-Disk Grinding
Automation
Service
Retrofitting
Talk to us, and we will
find your solution.
+49 7834 866-0
info@supfina.com
Eric Schäfer
editor-in-chief
Engineering with
High Precision
www.supfina.com

table of contents
cover story
The perfect connection
Special tools from Horn 6
materials & tools
Even composite materials no problem 9
“Marathon” tools with a license for precision 10
New high performance cutter for the highest demands on productivity 12
The best deep bores with PCD 13
processes
Burrless chamfering with world’s first V-shaped blade 29
Lightweight damper system for use in lightweight structures
Fraunhofer Institute for Manufacturing Engineering and Automation IPA 32
Digital transformation in tooth machining 36
machining center
Opening new industries with a Kern Micro HD around the globe 40
components
A partnership for an automated future 43
When precision is of the essence 44
Strong all-in solution for efficient quality inspections 45
EMO
Digitalization and sustainability 47
Powerful and productive 48
Meeting complex challenges with smart solutions 49
Precise, process-reliable and efficient milling 50
Machining center with tilting table for enhancing precision manufacturing 51
Ready to lead the future of machining solutions 52
Small differences that make a big impact 53
umati is back 54
Manufacture more parts faster 55
Customer care special exhibition area and machine highlights 56
Mechatronic solutions for metal working 57
news & facts 16
fairs 22, 58
impressum & company finder 59
4 no.3, August 2023

The new eCatalogue 2023
The complete cutting tool solution is now
available in a digital version!
cutting.tools/uk/en/ecatalogue
CERATIZIT is a high-technology engineering
group specialised in cutting tools and hard
material solutions.
Tooling a Sustainable Future
ceratizit.com

cover story
The perfect connection
Special tools from Horn
It was autumn 1955 and the wind was blowing the last
brown leaves from the trees. As Otto Dunkel watched his
leaf rake doing its job, he had a brilliant idea. That was the
birth of the wire spring contact. Today, ODU GmbH & Co.KG
(Otto Dunkel) is one of the world’s leading companies for
the development and production of connector systems. For
the production of the high-end connectors, the company relies
on precise Swiss-type turning machines and tools from
Paul Horn GmbH. For about 20 years the two companies have
been working together closely, to ensure that the demanding
machining tasks are optimised for producing the perfect connector.
The close partnership will continue, especially with
regard to the machining of lead-free brass and other alloys.
Similar to the individual twigs of his broom, Otto Dunkel
divided the contact surfaces into individual springs, resulting
in a multitude of contact points. The result was a revolution:
constant contact resistance and consistent contact pressure.
With this the weak point of message transmission systems,
namely the unreliable plug-in contact, was finally overcome.
Founded in 1942, the ODU group of companies now
has 2,500 employees worldwide. The headquarters of the
Bavarian company is located about 80 km east of Munich in
Mühldorf am Inn. ODU supplies connector systems, among
others, to the medical industry, the measurement and testing
sector, industrial electronics, the military and the automotive
industry. It is noteworthy that ODU developed the first highcurrent
connectors for electromobility.
For micro-machining and other cutting operations, ODU
relies on tool solutions from Horn and machines from Tornos
The S274 µ-Finish system is efficient for
micro-machining of components
Horn tools
“In the past we often ground tools ourselves for machining
special connectors. However, with quantities of
several hundred thousand per year, we need process-reliable
and productive tooling systems,” says ODU tool manager
Tobias Fuchshuber. “Our cooperation with Horn has existed
for about 20 years.” Horn field service representative
Michael Götze has been involved from the beginning: “During
this extended period we have been able to solve numerous
machining problems at ODU. Its employees are always open
6 no. 3, August 2023

cover story
The N105 broaching system can be adapted to
many applications
To ensure a good contact, a high surface finish is an
important quality feature of a plug connector
to new tool technologies and we often test new products there
as a result.” ODU relies on numerous Horn tool systems.
“The machining tasks at our company are very diverse. On
more than 175 sliding-headstock lathes we machine micro
components of a few tenths of a millimeter in diameter up
to parts of 0 30 mm”, says Fuchshuber. Tools from Horn are
used in all areas of production. From the µ-Finish system
S274 for sliding-headstock turning of micro components to
internal turning and grooving. At ODU 80 % of the material
processed is brass. Aluminum, copper and stainless steel
account for the remaining 20 %.
It’s the surface that counts
For contacts in particular, high surface quality is a decisive
feature. For turning contact pins, ODU relies in part on the
Horn tool system S274 in the µm finish variant. Grinding a
sharp and almost flawless cutting edge on a tool requires a
lot of know-how. Grinding wheels with the finest grits, special
grinding techniques and a microscope with 400x magnification
are necessary to ensure that the tool performs as
required. Every batch of the µ-Finish system is subject to
100 % inspection. Important criteria for quality assurance are
the high-tolerance surface quality of the rake and flank surfaces,
the center height and especially the sharpness of the
cutting edge. Irregularities on the cutting edge of more than
0.003 mm are considered to be out of tolerance.
For the production of a coupling of a wire spring contact,
Fuchshuber was looking for a new tooling solution. “The
problem with drilling the component is the special shape of
the base of the hole,” explains Fuchshuber. ODU manufactures
the brass component in seven different variants from a
bore 0 of 1.43 mm up to 3.6 mm. “Before we switched to the
Horn tool, we pre-drilled the holes and then bored them out
with a tool we ground ourselves,” says Fuchshuber.
DS cutter of special shape
In series production, however, problems arose due to impeded
chip flow. In addition, there was potential for reducing
the machining time further. With several hundred thousand
parts per year, this was a decisive factor. Horn provided
the solution with the DS milling system with internal coolant
supply. The milling cutters are ground with a special
shape. When plunging into the solid, a hole is produced with
the same shape at the base. All of the seven cutter variants
are ground with sharp cutting edges, which are uncoated.
The changeover to the milling tools resulted in the saving of
one process step and also in an increase in process reliability
due to the controlled chip evacuation. In addition, the cycle
time was significantly reduced. “Conversion of the seven tool
variants only took about twelve weeks. The speed with which
Horn reacts as well as the fast delivery noticeably shorten
the time it takes to change over our machining processes,”
no. 3, August 2023
7

cover story
The special tool for
broaching the location key
Broaching the location key was a
challenge in the tool design
says Fuchshuber. He relies on
a Tornos DECO 10 sliding-headstock
lathe to produce the component.
Working closely together for 20 years:
Peter Ortmaier, Tobias Fuchshuber and Michael Götze
sources HORN/Sauermann
Further special tools from Horn are
used for machining a casing bushing. For
two axial grooves, Fuchshuber relies on the
Supermini system type 105. The grooves have 0 of
11 mm and 7.7 mm. The special feature is that a thin-wall web
of 0.2 mm must remain between the two grooves. The required
tolerances are very tight. Here, too, a special tool optimised
for machining brass is used. The tool is sharp, uncoated
and has a polished rake face. Inside the turned part, a Supermini
tool broaches a 20 mm long, 1 mm deep,
fail-safe keyway in four strokes. The keyway
ensures that the plug can be pushed into the
socket in one orientation only. At the end of the
groove, an internal recess serves as a relief for the
broaching tool. This component is manufactured
at ODU on Tornos DECO 13 and DECO 20 lathes.
Broaching of a locating key
“We were given the special task of producing a connector
housing. We were required to broach a circular groove,
rather than a linear one. However, a locating key with a width
of 3 mm had to remain within 0 of 13 mm,” explains Götze.
“We previously embossed the key from the outside but wanted
to eliminate this operation,” adds Fuchshuber. The solution
was a broaching tool of oval shape with the form of the
key recessed on one side. During machining, first the inside
is turned so that a ring remains. Then the tool enters
the workpiece and commences the broaching process. Machining
is started at one position. As soon as the diameter
is reached, the spindle turns the workpiece through 90 °, a
process that is repeated four times until the inner diameter
is circular and the locating key remains in the correct position.
The total machining time for the broaching process is
around 20 s.
The successful cooperation between ODU and Horn will
continue to grow ever closer in the future, especially with regard
to the machining of lead-free brass. The elimination of
lead as an alloying element worsens the machinability of the
material. This presents users as well as tool manufacturers
with new difficulties. “Lead-free brass will present us with
new challenges in the productive machining of our components
in the near future. However, with tool partners such as
Horn ready to assist, we see ourselves well looked after in this
area,” says Fuchshuber. EMO 2023, hall 8, booth A24
further information: www.horn-group.com
8 no.3, August 2023

Even composite materials no problem
materials & tools
Glass, carbon and aramid fibers pose new challenges
for a wide range of industries worldwide.
Tyrolit now presents the comprehensive Tyrolit Power
range for efficient machining.
The leading Austrian company presented its innovative tools
for cutting, grinding, drilling, milling and surface finishing
of the most demanding workpieces made of composite
materials for the first time at JEC World 2023 in Paris,
the global trade fair for composite materials and their
applications.
Low weight, durability and freedom of design are
properties of materials that are normally mutually
exclusive – which is not the case in the composite industry.
The innovative materials are able to withstand high pressure
and at the same time support the trend towards lightweight
construc tion. These complex materials present numerous
industries with new challenges in production. Tyrolit
is the partner for solving new types of problems and
designing innovative production processes together with
their partners.
Thanks to decades of experience in the manufacturing of
grinding tools and numerous collaborations with renowned
machine manufacturers worldwide, the company is able to
provide its customers with economical and sustainable solutions
for the processing of composite materials. They have
been offering high-quality solutions for the surface treatment
of composites since 2017, and this portfolio is now
being complemented by tools for all applications.
Machining of composites with Tyrolit Power
The new Tyrolit Power range is specifically designed for
these difficult-to-machine materials and has been extensively
tested, resulting in highly efficient machining processes and
guaranteeing an unparalleled tool lifetime. Tyrolit’s portfolio
includes products for cutting, grinding, drilling, milling and
surface finishing of the most demanding workpieces with
hand-held machines, semi-automatic robots and on high-tech
CNC machines.
The new assortment offers solutions for every process step
for machining of composite materials and solves known problems.
With Tyrolit Power process reliability in the production
is increased and homogeneous surface results are facilitated.
The machines are equipped with special protective measures
to improve the safety and health of users. The new tools generate
less dust, minimize vibrations during machining and
support ergonomic working. The products are being used in
numerous industries, for example for grinding rotor blades
in the wind power industry, for matting surfaces in the aerospace
industry, and for machining lightweight components
in the automotive industry.
further information: www.tyrolit.com
from
IGUANA:
LASER-SHARP
AND ULTRA-PRECISE
ATION BW
INNOV 2021
Innovationspreis Baden-Württemberg
Dr.-Rudolf-Eberle-Preis

materials & tools
Extensive portfolio for automated electrode production
“Marathon” tools with a license for precision
oil, ideally with internal shaft cooling at the
same time. So surely a combination is out of
the question.
Not necessarily, because in the meantime
there are very good filter systems for liquid
cooling lubricants, making it an interesting
option to wet-mill copper and graphite electrodes
on the same machine. This results in
users achieving maximum flexibility as well as
better utilisation of the machines integrated
into the automated system. In combination
with ZECHA’s highly precise and reliable
milling tools, this enables optimally calculated
and safe production workflows and milling
processes.
Laser sharp and proven in mould making: the IGUANA series from
ZECHA Hartmetall-Werkzeugfabrikation GmbH is the diamond coated
solids carbide milling series with extremely sharp cutting edges and endurance
Consistently high quality and maximum flexibility aren’t only
key features in mould making. Maintaining maximum efficiency
means one has to use high performance, high-end tools.
Because once these are acquired, the next step comes: low manpower, automated
production. Unthinkable? ZECHA Hartmetall-Werkzeugfabrikation
GmbH is banging the drum for mixed machining with an intelligent tool
selection.
The mould making companies’ ability to compete depends completely on
their automation. In addition to machining, this especially includes the clever
connection and coordination of all manufacturing technologies needed for
component production. This includes erosion, laser machining, as well as
component cleaning and measurement. An essential aspect is the milling
of usually very demanding materials – the perfect area of application for
ZECHA Hartmetall-Werkzeugfabrikation GmbH’s high precision micro tools.
It’s all in the mix
At first glance some things just don’t seem to go together: who would ever
think of machining graphite and copper on the same machine? “Most people
immediately dismiss it.” according to Andreas Weck, application engineer at
the company. “But the solution is mixed machining! This is the machining of
different materials that usually aren’t machined with the same cooling lubricant,
in this case combining graphite and copper electrode machining – two
strategies that couldn’t be more different.”
This is because graphite is usually dry milled on specially configured
milling machines with particularly powerful extraction systems and the corresponding
ventilation. Whereas copper is impossible to dry machine and
therefore requires a differently configured milling machine with emulsion or
Laser sharp and high precision
IGUANA cutters are a good fit for all
non-ferrous metals
One tool series has already become the perfect
partner in mould making in a very short time:
the unique IGUANA cutter series. These solid
carbide tools with up to three cutting edges
have a sealed diamond coating resharpened
by laser. Dennis Thiermann, application engineer
at ZECHA, explains: “The coating process
inevitably leads to a cutting edge radius
of the same order of magnitude as the coating
thickness, which can be considerably more
than 0.01 mm. This is reworked by means of
a laser either on the rake and flank surfaces
or only on the flank surface. This gives us
a consistently sharp cutting edge radius of up
to 1 µm. At the same time coating defects, socalled
clusters, are smoothed out.”
Because of their sharp cutting edges,
IGUANA tools have become standard when
machining different materials, such as aluminum,
copper, all types of brass as well as simple
and fiber-reinforced plastics. These tools
are even used in the machining platinum.
In the meantime there are five sub-series.
In addition to the original range layered on
both sides, there are also tools with edge protection,
helix or shank cooling as well as helix
and shank cooling. These tools are available
as ball, torus and end mills, the series with
shank cooling as torus and end mills. Drills
are also available. The new 935 series completes
all of the copper electrode mould making
needs by being available in the usual free
lengths and corner radii.
10 no. 3, August 2023

materials & tools
A top performance
thanks to the lowest tolerances
In many cases this technology has already been able to increase
process reliability. “Above all, since the tool life and
dimensional accuracy can maintain an excellent level over
extremely long periods, users benefit straight away. In contrast
to PCD tools, which are usually only available with
one cutting edge in small diameters, IGUANA cutters have
up to three cutting edges,” says Mr. Thiermann.
The lowest possible production tolerances, such as an
impressive 2 µm concentricity and form accuracy of +/-
5 µm, optimise quality, especially when finishing fine surfaces.
This often eliminates time-consuming remachining
which in turn reduces process costs. Moreover, there is
an upward trend in overall economic efficiency thanks to
longer tool life and therefore few tool changes.
Further strong tool partners
Despite IGUANA’s strengths in mould making, there are
still a few partners in the ZECHA product range capable
of increasing ones possibilities. These include the graphite
cutters and the steel cutters from the PEACOCK range (including
CBN) and the new QUEEN BEE tools.
PEACOCK tools are the multi-talents for hard and powder-metallurgical
steels up to 70 HRC, such as cold and hot
work steels, PM steels, special alloys or tungsten copper
with more than 50 % tungsten content. There is an extensive
range with mould-optimised total and free lengths.
The F-series enable a very high metal removal rate and the
whole tool series produces excellent surface qualities.
capacity, they can withstand any marathon machining session –
unmanned, overnight or even the entire weekend.”
For hard cases: CBN
Occasionally in mould making, hard and powder metallurgical
steel of up to 70 HRC simply can’t be avoided. This requires
a particularly tough cutting material to withstand the intense
temperatures in the machining process. Cubic crystalline boron
nitride (CBN) is the ideal counterpart for such tough jobs,
as it combines a high hardness and fracture resistance, even in
interrupted cuts, with high thermal and chemical resistance.
“In a way, it’s a trick to heat up the material for machining,
making it softer which leads to longer tool life.,” explains Mr
Thiermann.
At the same time, CBN has a very high density and resistance
to cracking and diffusion. It enables a homogeneous and even
cut, which also contributes to very good surface finishes. Overall,
CBN cutting materials offer high reliability, tool life and
accuracy when machining steels of up to 70 HRC
High performance tool life champions
Not wanting to worry about precision, tool life and quality in
machining processes when mould making, it’s best to use tried
and tested milling tools. In order to get the most in terms of
efficiency, mixed machining and automation solutions show
the road into the future. “And,” as Mr Weck states, “with our
extensive tool portfolio, our tool users are well prepared for
current and future challenges!”
further information: www.zecha.de
The QUEEN BEE 589 series ball and torus cutters
promise process-reliable machining of steels up to 58 HRC,
nickel based alloys, titanium and special materials up to
1,800 N/mm 2 . The cost-optimised specifically for mould
making adapted tools are available 0 0.8 to 12 mm. Solid
tool properties, coupled with the latest coating technology,
increase tool life and minimise tool changes. Furthermore,
you get very smooth surfaces and less material adhesion.
Maximum precision and cutting quality
Both tool concepts, PEACOCK and QUEEN BEE, combine
the performance potential of the latest solid carbide grades
with finely tuned tool geometry and state-of-the-art PVD
coating. The carbide offers a high level of hardness and
toughness at the same time, making it very stable. Thanks
to their optimised micro-geometry, these tools achieve low
cutting forces and a smooth cut. The coatings possess an
impressively smooth and homogeneous surface, temperature
resistance, strength and damping, as well as the best
possible coating adhesion.
Thanks to the lowest manufacturing tolerances, a concentricity
of 3 µm and a shape accuracy of +/- 5 µm, these
series are particularly interesting for finishing fine surfaces.
Andreas Weck: “Both are perfectly suited for wet and
dry milling. This makes them the perfect choice for mixed
machining, automation and demanding applications with
long running times. Thanks to their high mechanical load

materials & tools
New high performance cutter for the
highest demands on productivity
The new HPC milling cutters from LMT Tools enable maximum metal removal rates
and the highest dimensional accuracy with first-class surface quality
LMT Tools is one of the most renowned experts in
the development and production of precision tools,
and sets regularly technological trends in the market
with its high innovative strength and tool expertise.
The latest coup: new high-performance milling cutters
for high-performance cutting.
The HPC family combines the proven DHC Premium, DHC
INOX Premium, DHC Slot and DHC Hardline tool series
and, thanks to improved technology, achieves a significantly
higher metal removal rate. Considerable increases in productivity
with optimum process reliability are thus guaranteed.
High performance cutting (HPC milling) requires highperformance
tools that can optimally withstand the strains
caused by the high cutting speed and feed rates involved in
the process and ensure cutting with as little vibration as possible.
With the new HPC family, the tool expert offers the perfect
solution. The cutting geometry, coating and cutting-edge
treatment have been specially adapted to the special requirements
of high-performance machining and enable maximum
metal removal rates and high dimensional accuracy with
first-class surface quality. The unequal pitch ensures maximum
smoothness and process reliability, while the surface
quality of the machined workpieces is a further advantage.
The optimum high performance cutter
for every material
Whether trochoidal, side, corner and groove milling or ramps
up to 0 0.5x – the HPC family is designed for a wide range
of applications. There are four versions available: HPC P,
HPC M, HPC UNI and HPC H. The HPC P is the specialist
for higher alloyed steels and castings with a tensile strength
of 900 N/mm 2 or higher. An edge protection bevel reduces the
load on the cutting edge and ensures optimal performance in
the demanding machining of abrasive materials. The HPC M
excels in the machining of austenitic steels, non-ferrous
metals and titanium. The positive cutting-edge geometry and
special coating ensure efficient machining of materials that
usually have higher toughness and are therefore difficult to
machine.
The HPC UNI is a three-flute cutter (all other variants being
four-flutes) and therefore provides a larger chip space.
With excellent chip removal, it is ideally suited for full slot
milling in a variety of materials (P, M, K, N and S). Each flute
has a different helix angle. The HPC H is the best choice for
hardened steel up to 55 HRC. Its targeted edge rounding results
in a particularly stable cutting-edge, allowing for very
high feeds in hardened and high-strength materials up to
1,600 N/mm 2 .
Maximum tool life and productivity
The new HPC family replaces the well-known DHC family.
By optimizing production processes and using state-of-theart
technology, tool life and productivity have been significantly
increased compared to the previous series. “With our
new high performance cutters, high cutting speeds and feeds
can be achieved, resulting in high chip volume and increased
productivity,” says Marcus Paul, global head of product management
and emphasizes: “Compared to the previous families,
we have managed to increase the metal removal rate by
more than 30 % and achieve a tool life increase of up to 70 %.”
Proving the technological leadership of the tool experts.
further information: www.lmt-tools.com
12 no.3, August 2023

The best deep bores with PCD
materials & tools
When the Schlote Group built a new factory in
Harzgerode in 2017, it was designed to mass produce
only a single part. MAPAL supplied all the cutting
tools. By optimising the tools, the foundation has now
been laid for a future with new products.
Schlote’s story begins in 1969 as a small workshop in
Harsum, where the company is still headquartered. Today
eleven companies with 1,800 employees belong to the Group.
The OEM has eight factories in Germany as well as further
manufacturing facilities in the Czech Republic and China.
Schlote Group customers include big car manufacturers, system
integrators and foundries. Schlote’s turnover stems from
engines (55 %), transmissions (39 %) and chassis (6 %).
Already at other sites a successful cooperation with
Trimet Aluminium existed, manufacturing finished car components
from cast blanks. The awarding of a contract for a
component by a major OEM, involving very high quantities,
led to a joint venture between Schlote and Bohai Trimet in
Harzgerode.
Stefan Frick (left) and Sebastian Swiniarski
inspect a finished clutch housing
Milling competence
right down the line
■ 45° Milling - Smooth cut and high metal
removal at extremely smooth running
■ 90° Milling - Highest productivity, cost
reduction and optimal distribution of cutting
force
■ HFC-Milling - High metal removal under the
most difficult conditions
■ 3-D Milling - Universal applicable tool
system for mould and die
■ Solid carbide milling - Over 1000 products
for every application
www.boehlerit.com

materials & tools
More than 4,000 clutch housings
per day
The part being manufactured in Harzgerode
is a clutch housing made of die-cast aluminum.
A single version of the automatic transmission
is being delivered to various major car
manufacturers, where they are predominantly
installed in vehicles with two-liter engines.
The bell housing connects the transmission to
the engine. While the transmission side is the
same on all the clutch housings, the other side
is adapted to the respective car manufacturer’s
engine. The differences are mostly small,
so the bell housing construction is 99 % identical
for all of the car manufacturers.
A manufacturing cell at Schlote is made up of three machining centers from
SW; two W06 double-spindle machines and a one6 single-spindle machine
Schlote Harzgerode GmbH is currently producing
4,000 parts per day. At over 80 % the
modern factory exhibits a very high degree
of automation. Five days a week around the
clock 120 employees work at the Harzgerode
site. Production can be expanded to six or
seven days a week if need be.
As is the case for the entire automotive industry,
the requirements placed on parts are
very high here. “The part is not only an adapter
flange, but also the back of the transmission.
The bearing seats thus require the highest
degree of precision”, explains Sebastian
Swiniarski, work preparation team lead at
Schlote. The part requires many bores with
different tolerances, whereby precision manufacturing
is needed down to the thousandth of
a millimeter.
Deep drilling is one of the machining steps that takes place on the
double-spindle machine; bores 180 mm and 141 mm deep are created
with an 8 mm drills from MAPAL
The first machining steps for the clutch housings occur on
double-spindle machines; while machining takes place at the back,
new parts can already be clamped at the front
MAPAL and Schlote can look back on
many years of effective cooperation. MAPAL
is therefore entrusted with supplying PCD
milling cutters (which create the defined
rough surfaces on which sealant is applied),
tap drills, reamers and an array of diverse
drilling tools. “We offer our customers comprehensive
solutions including the development
of entire processes”, says Stefan Frick,
MAPAL’s technical advisor to Schlote.
Successful improvement process
From the very beginning on a watchful eye
was kept on the implemented tools. Since
Harzgerode went into operation, analyses
have been performed continuously to find
possible weak points and optimise manufacturing.
Within the context of this continuous
improvement process, Schlote and MAPAL
have managed to achieve longer tool lives,
lower tool expenditures and higher production
quantities over years. While 3,600 parts
per day were produced at most in the beginning,
the limit has now been raised to 4,500
parts –without needing more machines.
14 no. 3, August 2023

materials & tools
The newest optimisation involves deep drilling for oil
channels used to change gears in the automatic transmission.
“We evaluate every month with our tool management
system which tools have to be exchanged how often”,
Swiniarski reports. “Time and again the deep drills have
proven to be particularly sensitive. As these drills are
relatively cost intensive, we have concentrated on them
to further cut our tool costs.” Quality aspects are also inherent
in tool wear as a blunt drill produces burrs at the
bore exit.
In this particular case, two of five deep bores are involved
with a 0 of 8 mm and cutting depths of 180 mm and 141 mm.
They run through the part from the side up to the bearing
seat in the middle. Up to now solid carbide tools were used
for this, which is standard for deep bores. Schlote was able
to achieve a tool life of 2,500 parts in this way. The load
monitoring of the machine already registered tool wear
starting at 2,000 parts though, and burrs could be seen at
the bore exit.
Significantly longer tool life with PCD
When it came to optimising the deep bore, plant manager
Tino Lucius, a former MAPAL employee, suggested PCD
variants. And so the partners developed the idea of deploying
a PCD tip for the deep drills. There was a lot to consider
during the implementation, Frick relates: “It is not possible
to construct this type of drill entirely out of PCD. Apart
from the high costs, the brittleness of the material is a problem.
There is also always the danger of chipping of the cutting
edges during interrupted cuts. Good cooling must also
be ensured as PCD is heat sensitive.”
For the new tool MAPAL started with the existing solid
carbide drill and inserted a PCD cutting edge at its tip. The
structure of the tool is reminiscent of a concrete drill with
a carbide tip. The manufacturers in Harzgerode are very
happy with the PCD deep drill’s tool life. While the solid
carbide drill’s tool life ends after 2,500 parts, the PCD
version keeps going reliably up to 15,000 parts. There is
further scope for improvement in machining challenges,
such as blowholes in the material and varying casting
quality. The partners are currently working on this together.
“We have occasionally been able to achieve a tool life of
40,000 parts. Naturally, we want to make this ultra-long tool
life the norm”, Frick stresses.
The future is electric
Clutch housing manufacturing at the site was planned to last
at least eight years with a peak output of 1.1 million parts
per year. This peak was surpassed in 2020. Production has
been ongoing for five years in the meanwhile with 900,000
parts produced per year.
Due to continuously improved productivity and the lower
production quantities, there has been time to address future
trends and produce different parts. The factory is already being
modified for this purpose. The first of two new projects
involves six different parts that Schlote is to produce for a
hybrid model of super sports car manufacturer.
In the other project Schlote’s expertise as a clutch housing
manufacturer is once again called for – this time for an electric
car. Schlote draws from the trend toward electric mobility
by supplying e-cars with transmissions as well.
For an innovative model with three gears, the connection
between engine and transmission is to be produced in
Harzgerode. Half of the factory capacity is currently being
converted. The production of parts for combustion engines
is to be ramped down to 50 %. In future hybrid cars
will account for 10 % and purely electric mobility for 40 %.
Schlote has already produced the first parts for the new
projects.
DIGITAL. DIVERSE. DRIVING.
kapp-niles.com
further information: www.mapal.com
The cutting data is the same as that of the solid carbide
drill at a spindle speed of 8,700 rpm, a feed of 0.3 mm/rev and
a cutting speed of 218 m/min. The new drill’s potential lays in
its considerably longer tool life, the resulting lower tool costs
and the higher process reliability. Less tool changes also
means less machine downtime.
Production at Schlote in Harzgerode involves a total of
ten manufacturing cells. Each cell is made up of three machines
from the manufacturer SW, two W06 double-spindle
machines and a one6 single-spindle machine. The parts are
machined in three clamping setups, whereby the doublespindle
machines handle the first two setups and finishing
takes place during the third.
Hall 11
Booth E06

news & facts
HELLER continues to invest in Changzhou
Production site to be significantly expanded
Recognising the importance of the large Chinese market,
HELLER has recently invested in its Changzhou
plant, creating the conditions to produce more than
100 machines per year on site. In the presence of local
politicians, numerous key customers and the HELLER
management, the extension building was officially
inaugurated June 16, 2023.
As far back as the 1950’s, HELLER was already looking far
beyond its European home market to China. The managing
directors at the time made important contacts and began
manufacturing machine tools for the local market. This
led to several close collaborations with local distributors. The
company was poised for growth, so in 2013 the Nürtingenbased
machine tool manufacturer set up its own subsidiary
in Changzhou, which is located in the center of the Yangtze
Delta. At that time, a 7,000 m 2 service and assembly plant was
built on a total area of 24,000 m 2 .
Since then business has picked up strongly. In the beginning
mainly with well-known companies in the commercial
vehicle industry. Since the early 2020’s, HELLER has also
increasingly won customers from the sectors of aerospace,
mechanical engineering, hydraulics etc. For several years
now the German company has been producing the universal
machines required by these industries locally in Changzhou.
This proved a crucial step because, according to Claude
Ballay, general manager of HELLER China, experience shows
very clearly that ‘local for local’ production is becoming increasingly
important in the Chinese market. He explains:
Regional machining center business in China is growing;
currently HELLER China mainly produces the 4-axis
H 6000 and the 5-axis HF 3500 and HF 5500 models;
the H 4000 and H 8000 machining centers and the
CBC 200 coating modules are also built here as needed
HELLER China has invested in its local subsidiary in
Changzhou, China, expanding its production and
service floorspace from 7,000 m 2 to 9,000 m 2
“Delivery times of three to four months are expected here
and we have to be able to meet them reliably. What’s more,
our customers understandably expect us to produce much of
what we sell here in the country.”
Accordingly HELLER began building its first machining
centers for the so-called regional market four years ago. Local
suppliers were contracted and in-house staff trained for
assembly and ongoing quality control. The new strategy began
to pay off very quickly. In spite of the Covid dip, business
in the universal machine market in particular has grown and
now accounts for almost half of total sales in China.
New building adds 2,000 m 2
In line with the ‘local for local’ strategy of the Chinese universal
machine business, the management of the HELLER
Group decided at the end of 2021 to expand the Changzhou
plant. Construction began in the spring of 2022, and about a
year later the new 2,000 m 2 building was completed and inaugurated
June 16, 2023 in the presence of 30 VIP customers,
local politicians and the HELLER management.
A total of 9,000 m 2 of production floorspace is now available.
The expansion has been key in enabling the company
to produce a greater volume of machines in an efficient and
cost-effective manner.
further information: www.heller.biz
16 no.3, August 2023

news & facts
HELLER cooperates with
Porsche Penske Motorsport
HELLER is now the new technology partner of Porsche
Penske Motorsport. The cooperation was visible for the
first time at the legendary 24 hours of Le Mans on June
10 th and 11 th , 2023.
“HELLER and Porsche share the same values: precision in
detail and sustainability in development and production,”
describes HELLER CEO Dr. Thorsten Schmidt the new partnership.
And Thomas Laudenbach, vice president of Porsche
Motorsport, adds: “We want to bring innovative technologies
and sustainability to motorsports and be at the forefront of
new developments.”
As part of the cooperation, the company based in Nürtingen
will now work very closely with Porsche Motorsport and
the entire technology network. “In this way we are expanding
our customer potential and can accelerate our growth in
world markets,” CEO Dr. Thorsten Schmidt is looking forward
to the cooperation.
With the newly developed endurance racing car Porsche
963, Porsche Penske Motorsport is embarking on a historic
year in motorsports. This is because the legendary race in
Le Mans took place for the 100 th time this year. Further appearances
in the WEC racing series will follow, including
in Italy (Monza) and Japan (Fuji). And always there: the
HELLER brand logo clearly visible on the Porsche 963.
Furthermore, Porsche Penske Motorsport is showing its
colors on the important US market for HELLER: the team is
also participating in the famous IMSA racing series, which
includes appearances on famous tracks such as Daytona or
Indianapolis.
Both partners are planning numerous events for HELLER
customers. For example, the Porsche 963 will be seen at important
industry fairs at the HELLER booth.
As a celebration of the 100 th 24-hours of Le Mans, Porsche
Penske Motorsport took part with a special and festive
livery. Due to its colorful design, the Porsche 963 was given
the name: “Butterfly”.
further information: www.heller.biz
KENOVA set line V346
Precision and robustness
for Smart Production
EXPERIENCE
KELCH PRECISION
Hall 4, Stand B53
• Tool presetter with software EASY
• CNC-spindle autofocus
• Mechanical tool clamping
• CMOS-Camera repeatability ±2 µm
• Tool Holder SK 50 with integrated calibration balls
• An exceptionally quiet servo motor
• Thermo-label printer
QR-Code: scan and
watch product video
KELCH GmbH · Werkstrasse 30 · 71384 Weinstadt
Tel.: +49 (0)7151/20522-0 · info@kelch.de · www.kelch.de

news & facts
EMAG starts construction of a new plant in Mexico
On June 19, 2023, the symbolic groundbreaking ceremony took
place for the new plant of the EMAG Group in the San Isidro
Business Park in Querétaro, Mexico. This marks the start of an ambitious
investment program of the EMAG Group in the region.
In the last decade the Mexican market has developed into an attractive
production location for the USMCA (“United States Mexico Canada
Agreement”) free trade zone, formerly NAFTA. This is due to several factors:
the strategic location, attractive framework conditions for investment,
a high level of training, a solid infrastructure and a long tradition in
manufacturing.
The symbolic groundbreaking ceremony for the new plant of the EMAG Group
took place in the San Isidro Business Park in Querétaro, Mexico
The global crises of recent years have led to
a rethinking of the value chain and production,
towards so-called nearshoring. Mexico
has benefited from these crises and the misalignments
of production. Industries such as
automotive, aerospace, electronics and consumer
goods are investing billions in existing
and new production capacities.
But Mexico is not just an extended workbench.
Thanks to its good level of education,
the country is home to more and more
research and development sites of global
companies. Against the background of this
dynamic development and ever shorter investment
cycles, the construction of the new
EMAG plant is another step in the company’s
20-year success story in Mexico. In the future
the expansion of local competence and value
creation will be of great importance.
Since entering the market in 1997, EMAG
has continuously invested in its presence in
Mexico. After establishing a branch in Mexico
City in 2003, a new headquarter was opened
in Querétaro in 2015 with a production
area of 420 m². EMAG Mexico was awarded
Supplier of the Year in 2010 (AAM) and 2016
(Sisamex) and was able to realize its first turnkey
project in 2019.
further information: www.emag.com
MAPAL moves into new building in Komorniki
MAPAL Narzędzia Precyzyjne (MAPAL precision tools) in Poland got a new head office. MAPAL acquired a
5,000m 2 premises in Komorniki, not far from the previous site in Poznań. A modern and generously equipped
office building has now been erected there, the grand opening was in March 29, 2023
In Poland the company serves the production
plants of international automotive and
mechanical engineering manufacturers
among others. A collaboration with the commercial
agency Gallo-Ex in Poznań that began
in 1996 led to its takeover in 2002. Since 2005
the branch office has been trading as MAPAL
Narzędzia Precyzyjne. In 1997 MAPAL received
a major order in Poland from a diesel
engine manufacturer in Tychy, and in 2004
it took on its first tool management project
for the VW plant in Poznań. MAPAL’s reamers
entered the Polish market as far back as
the 1970’s. At that time the buyer was one
of the largest ship engine manufacturers in
the country.
further information: www.mapal.com
18 no.3, August 2023

news & facts
Platinum Tooling
now represents
Henninger
RECYCLED
PACKAGING
ROCKS
PACK. USE. RECYCLE. REPEAT.
EMO
Hannover
18. - 23.09.2023
Stand No. D82
Hall 4
Platinum Tooling, the importer of live tools,
angle heads, marking tools, Swiss tools and
multiple spindle tools manufactured by various
global suppliers, is now importing Henninger
Speed Increasers for North America. The announcement
was made by company president,
Preben Hansen, at headquarters in Prospect
Heights, Illinois, near Chicago.
Henninger is a manufacturer of specialized equipment
and precision machine tool accessories. Spindle speeder
types including mechanical, air and electric motor
driven styles are all available.
These speed increasers help maximize productivity by
achieving a higher spindle rpm that is required for certain
applications in today’s marketplace. Small diameter
tools require rpms that are sometimes not possible
to reach with existing machine tools. In addition they
allow for less wear and tear on the machine’s spindle
when it is not required to run at its maximum rpm.
Mechanical speeders are available with up to a 1:8 gear
ratio and a maximum speed of 50,000 rpm. Air speeders
can run continuously at up to 80,000 rpm and high
frequency motor spindles can maintain up to 80,000 rpm
with high torque, and have variable speed options.
Many of the speeders have automatic tool change
capabilities and are modular in design to offer the customer
greater flexibility. Henninger also manufactures
custom angle heads, live centers, face drivers, and live
chucks. In addition Henninger is the premier manufacturer
for center grinding machines.
further information: www.platinumtooling.com
www.rose-plastic.com

news & facts
ARCH Cutting Tools acquires VR Wesson
ARCH Global Holdings LLC Company (ARCH) announced the acquisition
of VR Wesson, a manufacturer of standard and special inserts,
tool holders and milling cutters located in Cape Coral, Florida.
The company will join ARCH Cutting Tools, a division of ARCH and
industry-leading, American manufacturer of solid round and indexable
metal removal tooling.
ARCH Cutting Tools is headquartered in Bloomfield Hills, Michigan, and
serves the medical, aerospace, defense, automotive, energy, agriculture and
general industrial markets. ARCH Cutting Tools has facilities across the
Eastern U.S. and is dedicated to engineering high-performance standard
and custom tools that increase efficiencies for end-users. VR Wesson will be
consolidated into ARCH Cutting Tools – Orchard Park, and will expand the
company’s existing insert offering via ARCH Specials.
“ARCH Cutting Tools is proud to announce
the acquisition of VR Wesson, whose
advanced manufacturing technologies and
key accounts will be consolidated into our
Orchard Park, New York facility,” said
Robert Gralke, president of ARCH Cutting
Tools –Orchard Park in Buffalo.
“We are particularly excited to bring laser
PCD finishing capabilities under our roof,
which will increase our team’s efficiencies and
expand our product offering to key industries,
including automotive and medical.”
further information: www.archcuttingtools.com
Boehlerit Oberkochen celebrates its
25 th company anniversary
At the end of June the carbide pioneer Boehlerit from Kapfenberg/
Austria celebrated the 25 th anniversary of its German production
company in Oberkochen. As part of the celebrations a tribute was
also paid to long-serving employees.
Cutting material and tool specialist Boehlerit ensures process reliability and
efficiency worldwide with cutting materials, semi-finished products and precision
tools as well as tool systems for milling, turning, drilling and forming.
The company, which was founded in 1932 and has been family-run since
1991, is part of the Brucklacher Group, which Boehlerit forms together with
the two other legally independent sister groups – Leitz and Bilz. The Boehlerit
Group employs over 800 people worldwide at three production sites and
international sales companies.
The Oberkochen production site, which specialises in the manufacture of
high-quality wear products, celebrated its 25 th anniversary June, 30, 2023
with its workforce and numerous invited
guests. The high technical requirements and
the tight deadlines of the tool manufacturer
Leitz from Oberkochen to deliver profile tools
for hard machining express in a maximum of
five days led to the establishment of the carbide
production in Oberkochen in 1998.
Boehlerit now has had one of its production
sites in Oberkochen for a quarter of a century
and has built up an outstanding reputation for
its high-quality products.
The celebration took place in the festively
decorated Ölweihersaal at the Leitz company
and gave the guests the opportunity to experience
the history and development of the
company first hand. The sales manager of
Boehlerit Germany, Mr. Thomas Renfordt,
welcomed the guests. In his speech the managing
director of Boehlerit, Mr. Johann Werl
from Kapfenberg, emphasised the significance
of the anniversary and highlighted historical
aspects. At the same time he underlined
Boehlerit’s future viability in his outlook. The
company plans to further expand its position
in the market and offer new innovative solutions
for the industry. With a strong team and
a clear vision Boehlerit is ready to successfully
shape the next 25 years.
The chairwoman of the supervisory board
and shareholder, Dr. Cornelia Brucklacher, expressed
her sincere thanks to all who are or
have been involved in the success of Boehlerit
up to this date and wished the company continued
success and innovative strength.
further information: www.boehlerit.com
20 no.3, August 2023

Another crucial step towards becoming
carbon neutral by 2025
news & facts
CERATIZIT, part of the Plansee Group, has achieved
a major milestone on its journey to becoming carbon
neutral by 2025. Since the beginning of 2023,
production operations for the carbide specialist
have been powered by over 99 % green energy from renewable
sources.
As part of an ambitious sustainability strategy,
CERATIZIT has been gradually switching to renewable energy
sources for energy needs at its production sites. Now 99 %
of CERATIZIT’s energy requirements come from renewable
sources – a claim that is backed up by corresponding certificates
from its energy suppliers. As such, the carbide specialists
have reached their first milestone on the path to becoming
carbon neutral by 2025. Switching the majority of its
energy supply to renewable sources has helped the company
immediately cut its corporate carbon footprint (CCF) by
over 20 %.
Fixed calculation basis for carbon-cutting targets
The company has based its carbon-cutting targets on the figures
from its 2020/2021 business year, in which CERATIZIT
emitted almost 176,000 metric tons of CO 2 e (carbon dioxide
equivalent) according to the GHG protocol (Greenhouse
Gas Protocol). Around a quarter of the company’s emissions
fall under scope 1 of the protocol (direct GHG emissions) and
a quarter from scope 2 (electricity indirect GHG emis sions),
while around half fall under scope 3, which stem in particular
from purchased goods and services as well as employees’
trips to and from work.
“With these final figures we have the necessary information
to take the first steps to reducing our carbon footprint.
Switching to renewable energy is only the first step in this
process, but one that has enabled us to reduce our footprint
by more than 20 %,” explains executive board spokesperson
Andreas Lackner. With the figures now available the company
will decide on further measures to be taken over the next
few months to reduce the company’s corporate carbon footprint
(CCF) by at least 35 % as currently planned by 2025.
The company has set itself the target of reducing its
2020/2021 CCF levels by 60 % through additional measures
by 2030, such as switching to ‘green’ hydrogen. The company
plans to achieve ‘net zero’ by 2040, ten years ahead of the
targets specified under the Paris Agreement.
further information: www.ceratizit.com
Precise and
productive
CBN profile grinding discs
Liebherr-Verzahntechnik GmbH
EMO: September 18-23
Hall 11, Booth F37
One-, two- or three-ribbed CBN profile
grinding discs for internal gears
– High-quality internal gears for low-noise use in gearboxes
– Increased load capacity due to the high residual
compressive stresses with CBN grinding
– Individual grain sizes for different applications
– Shorter grinding times
– Roughing and finishing in a single process
– Longer tool life
– Time-consuming dressing not necessary with CBN tools
Liebherr-Verzahntechnik GmbH, tools.info@liebherr.com, www.liebherr.com

news & facts
fairs
5 th leading trade fair for deburring technology
and precision surface finishing
Whether the mobility and energy transition, sustainability, health
or safety is involved – global megatrends have a profound effect on
industrial production. They’re also impacting demands placed on
burr-free components, as well as cleanliness and surface finishing
quality. As the only international trade fair for deburring technologies
and precision surface finishing, DeburringEXPO presents corresponding
offerings in a concentrated fashion which is unparalleled
by any other event.
The bilingual expert forum and various theme parks will also ensure an
effective transfer of knowledge at the 5 th leading trade fair at the Karlsruhe
Exhibition Center October, 10 th to 12 th , 2023.
Ultrasonic deburring takes place in a water basin in which components
are advanced to the high-frequency ultrasonic sonotrode
image source: ultraTEC
The right process for every application
“Thanks to its multi-industry, multi-material focus, DeburringEXPO supports
companies from all industry sectors in their search for suitable processes,”
reports Gitta Steinmann, project manager at private trade fair promoters
fairXperts GmbH & Co. KG. “The entire spectrum of technologies,
processes, tools and services for deburring, edge rounding, cleaning and
surface finishing are presented. The strengths and the limits of various processes
ranging from mechanical deburring with tools to vibratory grinding,
brush deburring and blasting with solid and liquid media, right on up to ma-
chining with special technologies, can be discussed
directly on site.” The latter includes, for
example, ultrasonic deburring which makes it
possible to selectively deburr edges and crossdrilled
holes in a fully automated, verifiable
process. Since this energy-efficient process can
be used for nearly any material, the range of
workpieces covers everything from micro parts
for the optics and watchmaking industries to
precision tools for machining, all the way up
to components used in machinery and vehicle
manufacturing weighing 15 kg.
Abrasive flow machining (AFM) also covers
a very broad range of applications. It’s used
for the deburring, edge rounding and polishing
of components in the automotive and aviation
industries, as well as in energy technology,
fluid and medical engineering, extrusion
technology and mould and tool making. The
strengths of this process result from its ability
to machine internal areas and surfaces which
are difficult to access, for example in additively
manufactured components.
In the case of ECM (electrochemical machining),
the machining process is based on
the anodic dissolution of the respective metal.
Nearly all metals can be machined, in particular
high-alloy materials such as nickelbased
and titanium alloys, and hardened materials.
In addition to deburring, selective
edge rounding and polishing, the technology
is also used for contouring and shaping components,
as well as for burr-free drilling – for
example in the aviation and aerospace industry,
the automotive and toolmaking sectors, in
medical, microsystems and energy technology.
Laser deburring is an effective method for
removing fine burrs and flakes from the outer
contours of very delicate, thin-walled workpieces.
Even the edges of drill-holes with diameters
of just a few tenths of a millimeter
can be machined. The process is also distinguished
by very high processing speeds.
Thermal energy machining (TEM) permits
the simultaneous removal of external
and internal burrs by means of vaporisation.
It’s used primarily for metal workpieces such
as hydraulic manifolds, and for components
made of thermoplastics from which internal
and external burrs have to be removed – even
from very difficult to access places.
further information: www.deburring-expo.de
22 no. 3, August 2023

symposium
news & facts
VDW symposium
attracted attention
in Vietnam
The VDW (German Machine Tool Builders’ Association),
Frankfurt am Main, staged its third symposium
in Vietnam’s capital Ho Chi Minh City June 12
to 14, 2023. Ten German manufacturers showcased
innovations in manufacturing technology – machine
tools from Germany.
“The Vietnamese market has been enjoying very strong
growth recently, and we are now the fifth-largest supplier
here. And so it is only logical for our industry to return
here in person to attract more attention,” says Gerda
Kneifel, VDW ambassador at the symposium in Ho Chi
Minh City. Ten German manufacturers were on hand at the
event: Alzmetall Werkzeugmaschinenfabrik, Altenmarkt,
the Chiron Group, Tuttlingen, Gleason Corporation,
Ludwigsburg, Grob-Werke, Mindelheim, Maschinenfabrik
Berthold Hermle, Gosheim, Index-Werke, Esslingen, Open
Mind Technologies AG, Wessling, Röders GmbH, Soltau,
Siemens AG, Munich, and the Trumpf Group, Ditzingen.
They presented their latest machines, solutions and services
for Vietnam. 121 participants from the most important
customer industries– the electronics, textile and food industries
as well as the metal production and processing sectors
– accepted the invitation of the VDW and the German--
Vietnamese Chamber of Foreign Trade. Being the best response
since the first Vietnam symposia was held in 2016.
“We need to raise the efficiency of our machines, and automation
is a further very important aspect for us. The symposium
gives us the opportunity to get in touch with German
companies that offer high quality software solutions
and that are very well organized,” says Cai Minh Giac, vice
director of Phuvinh Technology Mechanical Ltd. from Ho
Chi Minh City.
Among the ASEAN countries, Vietnam has become an
attractive industrial location and an important trading hub
with increasing industrial production. The country is expanding
its domestic production in order to manufacture
higher-quality products, reduce costs and at the same
time protect itself from international supply bottlenecks.
It needs machine tools to achieve this. With a market volume
of € 805 million, Vietnam is the 15 th largest machine
tool market in the world. Nearly all of its demands is met by
imports. Laser machines are on top of the required machine
groups, followed by presses and lathes. However, the machine
groups which are needed are constantly expanding.
“Vietnamese imports are dominated by machinery from
China, Korea, Japan and Germany,” explains Marko Walde,
chief representative of the German-Vietnamese Chamber
of Foreign Trade (AHK Vietnam). “German goods have
an excellent reputation in Vietnam and are highly valued.
And there are great opportunities for German exporters as
a result of the strong demand in Vietnam, the modernization
of production and the EVFTA free trade agreement.
More than ever Vietnamese entrepreneurs accepted
the invitation to the symposium
source: AHK Vietnam
Machinery imports totaled nearly $ 46.3 billion in 2021, 24.3 %
higher than in 2020. The most popular types of machinery and
equipment imported in 2021 included medical equipment and
tools, followed by batteries, electrical switchgear and wireless
telecommunications equipment.”
German exports to Vietnam increased from € 12.9 million in
2021 to € 19.5 million in 2022. The country thus rose from 47 th
to 41 st place among the most important customer markets for
German manufacturers. The Vietnamese market will remain
attractive in the medium term.
5-axis machining centre
F 6000
Designed for Production - with the 5th axis
in the tool for high-performance and flexible
series production.
further information: www.vdw.de
Premiere @ EMO
18–23 September 2023
Hall 12 | Booth C68
More information:
www.heller.biz/en/emo
no.3, August 2023
23

news & facts
LACH DIAMANT – 100 Years
Tradition. Passion. Innovation
part 6:
The start of CBN hard turning
Turning instead of grinding
Company founder Jakob Lach, 1894-1984
(photo taken in 1980)
Dear readers, in the last article
(compare part 5: https://tinyurl.com/
lachdiamant5), you could read about the
introduction and beginnings of polycrystalline
diamonds (PCD) for the superior
cutting of aluminium and other nonferrous
metals and composite materials;
this happened – from today’s perspective
– exactly 50 years ago.
Today, I am taking you back to the
events of 1974.
I will begin with an anniversary, for once a
personal occasion. On September 13 th , 1974,
my father was celebrating his 80 th birthday
with all his employees in the great hall of the
“Kurhaus Wilhelmsbad” in Hanau.
Even at this age, Jakob Lach was still the
guarantor of good purchases of natural
diamonds from global markets, mainly from
Belgium, and, back in those years, natural
diamonds were still much needed for diamond
dressing tools and for turning tools.
From my study of balance sheets in my possession,
I could see that the sales of LACH
DIAMANT® had more than doubled between
1969 and 1974.
Jakob Lach celebrated his birthday on a
big scale with all his employees in the Kurhaus
Wilhelmsbad in Hanau, but preferred to
celebrate with the smaller group of his
diamond cutters in his backyard.
24 no. 3, August 2023

news & facts
At this point in time, natural diamond tools
were still the main sales and profit factor,
followed closely by the massively emerging
diamond and CBN Borazon® grinding wheels
and polycrystalline diamond cutting tools under
the name of dreborid® PCD.
Back then, namely in 1972, my father took
me on as a limited partner, and the sole proprietor
company “Jakob Lach” became
“Jakob Lach GmbH & Co. KG” – in short
LACH DIAMANT®. The company expanded
in size. The production of diamond and CBN
grinding wheels had already taken on its own
status, and was managed by Gerhard Iffland
and Kurt Hemerka, and was located at the
newly established factory 2 at Fasanerieweg in
Hanau.
The same applied to the expansively growing
production of polycrystalline and natural
diamond cutting tools at the main factory at
Bruchköbeler Landstrasse 39-41 under Kurt
Wagner (†), Gerhard Mai and technical engineer
Günter Hobohm.
Jakob Lach himself was ever-present as the
much sought-after expert on natural diamonds.
Advertising brochure for the Hanover spring tradeshow in 1975
Back to 1974: as history tells us, the terracotta
army of 7,000 life-sized figures was discovered
in China; Hewlett Packard succeeded
in making the HP65, the world’s first programmable
pocket calculator; and the first
VW Golf was launched on the market.
Euphoria, ahead of time
Back to LACH DIAMANT®: maybe, at
least some of you will remember our slogan
“Borazon® – Abrasive of a new Era” which was
communicated in 1969, during our first presentation
of a Borazon® CBN grinding wheel
at the Hanover spring tradeshow. In part 5
of this series you could already read about
how my exuberant imagination played a trick
on me. Due to my personal euphoria for the
new abrasive Borazon® (Trademark General
Electric), it was clear to me that GE’s announcement
of a new abrasive could only be
a Borazon®/CBN product. However, I was
wrong. Instead of a cutting material made
from CBN, much like Borazon®, GE surprised
us in 1973 with the presentation of polycrystalline
diamonds (PCD). Then we knew!
A year later, in 1974, another surprise
followed, and on top of that from an unexpected
direction, that is to say, from Moscow.
Via Hempel, at that time a company dealing
with imports of silicon carbides, I was asked
whether we had any interest in a synthetic
Elbor CBN aggregate, sintered into a matrix
product named “Elbor” for cutting metal. Apparently, they had become
aware of LACH DIAMANT® because of our PCD activities. “Elbor, yes, of
course,” if this should be the fulfilment of my wish for a “Borazon®” cutting
material.
no.3, August 2023
25

news & facts
Center Kurt Wagner (†), on the right
Horst Lach, during the flight from
Moscow to East Berlin
I agreed to travel from East Berlin to Moscow.
Product manager Kurt Wagner (†) and I landed
in Moscow a few days before Christmas 1974.
Ministers of the Soviet Food Department
(apparently at that time responsible for the
Russian diamond industry) welcomed us in a
very friendly manner. A special highlight was
an evening invitation to a “dacha”, far outside
of the zone allowed for foreigners, as we
were told with a wink. We had Vodka, and so
many shots of it that my companion was feeling
quite ill, despite his attempts to refuse it.
According to the homepage of V-Bakul Institute for Superhard Materials, the
facility was largely destroyed by the first missiles aimed at Kiev, shortly after the
beginning of the war in Ukraine; shown here is a part of the institute’s premises
Our “Elbor” business almost became a minor matter. The product was a
pure pressed CBN body with a size of 0 8 x 6 mm. The delivery contract stipulated
delivery exclusively via the company Hempel. At the end, we were invited
to a “spontaneous” helicopter ride to Kiev in order to meet Professor
Bakul from the “V-Bakul Institute for Superhard Materials”. For understandable
reasons, we had to decline. It would have been interesting, that is for
sure. Today, in 2023, we could not make up for it; last year, the entire complex
of the institute was destroyed by some of the first missiles on Kiev.
Shopping adventures in Moscow
Before our flight back, and thinking of the upcoming Christmas holiday, we
went for a last shopping trip at Gum’s department store. We did not have
much time. A very popular display of large Babuschkas (rag dolls) on the
second floor caught our eyes. Each one of them like a “grandma with spectacles
on her nose, and with a flowing big skirt.” “This might be something for
our little ones.”
This is how you can picture the doll
purchased at Gum’s department store;
45 cm large, meant for use as a coffee cosy
(photo credits ebay)
We were caught in the order process, which, at this point, was still unknown
and confusing to us. We communicated the order quantity with
“hands and feet,” calculated the total on a wooden slide rule. We paid with
our last remaining roubles, and we then had purchased about seven of the
voluptuously large Babuschkas. No explanations from me about the further
course of events… (Only this much: the above-mentioned dolls turned out to
be coffee cosies.)
26 no. 3, August 2023

news & facts
At the Moscow airport lounge, we were already
expected. “Unfortunately there would
be a delay in our departure, the airport was
blocked off. A big shot was expected: president
of the state council, Willi Stoph.”
Afterwards, during boarding into the tubeshaped
Tupolev plane, our assistants prevented
us from going into the normal coach area,
and guided us towards the first-class seats.
That was good (see photo, left side). Until the
East German captain of Interflug asked us to
stop photographing because we were now over
Russian territory (no one suggested to reduce
our intake of drinks …)
Hours turn into minutes
Back in Hanau, we started the new year of
1975 with first preparations for the Hanover
tradeshow in spring. What do we do with
“Elbor”? Once again, chance came to our rescue,
and, most significantly, via Borazon®:
A “customer problem” occurred during the
polishing of a metal-powder-coated cylinder.
The customer found the grinding time with a
CBN grinding wheel too long. “Well, we could
try this compact CBN, this “Elbor” material.
Thought, and done.
Soldering, like with PCD, was unsuccessful
without a solderable carbide carrier. Soldering
in a vacuum was at that time no option,
so the only alternative was to sinter the
“Elbor” aggregate. Initially, the first attempt
with a turning steel, made in such a way, was
already successful. “This will be our tradeshow
highlight; we will demonstrate it on a
Weiler turning lathe.” And so, it happened
at the Hanover spring tradeshow; the “new”
product was successfully introduced under
the name “dreborid®-G-AS“ for machining of
metal-powder-coated turning parts. For the
first time this resulted in minutes of turning
time instead of hours of grinding time, and
with almost polished surfaces. The first step
toward better performance and efficiency during
hard turning was made.
Initially it was only a market niche for
powder manufacturers who propagated the
metal powder coating process – at that time
especially Metco (today Oerlikon-Metco) and
Castolin – for them, the dreborid®-G-AS turning
tools were like a present.
Their customers complained too much
about high grinding times during the levelling
of flame-sprayed turning parts, coated
with alloys of nickel, chrome and tungsten
carbide – no matter whether it was for repairs
Hanover spring tradeshow in 1975 –
first introduction of dreborid®-G CBN lathe tools for
turning sprayed-on materials, HSS, cast and high-alloy hardened steel
or wear protection. Turning instead of grinding immediately resulted in up
to 90 % reductions in time. During this phase, Metco and Castolin provided
repair kits (developed by us) to all their application technicians. The kits contained
one dreborid®-G-AS turning tool and a specially designed dreborid®-
G-Diamond grinding wheel.
Due to CBN’s lower hardness, compared to PCD, it was possible to regrind
cutting edges yourself, even with diamond grinding wheels.
Encouraged by these first experiences, we let our search be guided for
other possible applications by the positive experiences with the use of
Borazon® CBN grinding wheels. In fact, both removal processes, grinding
no. 3, August 2023
27

news & facts
and turning, work well with materials of 58
and 62 HRC, for example high-alloy hardened
steel. We realised that from now on, there
would be an increasing “gap” between grinding
with CBN and machining with polycrystalline
CBN cutting materials, independently
from continuous attempts of the manufacturers
of cutting tools to break this tendency with
newly-developed carbide and ceramic types.
The turning of high-alloy hardened steel
was at that time purely experimental, especially
because our initial fear was gradually
confirmed. The composite body with 0 8 mm,
delivered as “Elbor”, could only be used up
to approximately 35 % when mounted to the
holder with our chosen fastening; beyond
that, the body would break out. What the
CBN body was lacking for a stable connection,
was a solid solderable carbide base, as known
from polycrystalline diamond (PCD).
Possibly alerted by our success with
dreborid®-G-AS, the manufacturer General
Electric informed us at the end of 1975 that
they could now also offer polycrystalline CBN
blanks but now, with CBN tightly connected,
and with a solderable carbide base.
Gaining Speed
LACH CBN tools for turning and milling
of high-alloy hardened steel, and known under
the name dreborid®-G, could now gain
further momentum. Each day brought new
results and more satisfied customers, and it
became part of the 100-year history of LACH
DIAMANT®.
However, we developed even further. Without
the new buildings, a new office building
and factory on the premises of Bruchköbeler
Landstr. 41, and the large, rented facility at
Fasanerieweg, we would have by far met our
capacity limits, even back then. In addition,
the turbulent developments in the area of
polycrystalline cutting tools and in the production
of diamond and CBN grinding wheels
took their course far too quickly. By dynamically
tackling the new technologies for grinding
hardened steel (initially only offered by
General Electric in 1969), Borazon®/CBN
abrasive grits, and in 1973 also polycrystalline
diamonds, the LACH DIAMANT® company
had become like a pioneer and was now a constant
factor in the market.
In 1974/75, cutting tools under the name
dreborid®-G were added to the portfolio, adver -
tising to turn “hours of grinding into minutes
of turning”, especially for super-hard abrasive
materials. This was actually unbelievable!
Dreborid-G-AS,
used during the machining of metal-powder-coated wear components;
hours of grinding time “turned” to minutes of turning time
“Now, we can take our time and build on this,” my father and I thought.
But, as already mentioned, the future held further developments for LACH
DIAMANT®, all determined by sudden chances, courage and determination
when seizing new and suddenly available opportunities…
Yours, Horst Lach
PS: some articles of our 100-year anniversary are still to come; if you are
interested, the first five parts of this article series, going all the way back to
the founding of the company, can be found here:
https://bit.ly/anniversary-series
further information: www.lach-diamand.com
28 no. 3, August 2023

processes
Burrless chamfering with world’s first V-shaped blade
Nowadays, as the needs for environment friendly and value-added
products increase, more parts are made lightweighted and highly functional.
For this reason, increasing numbers of workpieces are lower in rigidity
because of the complex shape, and difficult to cut because of enhanced
strength. Therefore workpieces are increasingly more difficult to cut.
Especially in medical and aircraft industries, additive (AM) is adopted to
efficiently produce parts in complicated shapes.
However, at mass production sites in the automobile industry, where
monthly hundreds of thousands of vehicles are manufactured, use of 3D
printers as replacement for metal molds is limited, because of costs and production
speed reasons. Therefore the cutting process will remain essential in
the future. When cutting the workpieces in mass production, increasingly
difficulties can occur, opposing to small production, since in mass production
stability is required.
For example, when the rigidity of the workpiece is lowered, there may
occur problems, such as vibrations, lowered surface roughness and change
in size, affected by the change in machinability caused by a different lot,
lowered tool sharpness by tool wear and changing cutting resistance. This
uniformity in continuous machining can lower the process quality, leading
to lowered workpiece quality.
This not only applies to the size accuracy. When you think of the process
of manufacturing a part throughout to the finish, it also affects deburring.
Burrs formed in the cutting process can vary in size and shape because of the
change in material and tool wear. There are
different possibilities to remove burrs, which
can cause instability in mass production.
Production engineers are required to not
only know the accurate size but also burr conditions,
which is part of the product quality,
and requires to take necessary measures to
secure stability in mass production by equipment,
jigs, tools and machining methods.
Design specifications
have an effect on
the deburring process
When a workpiece is cut, burrs will be formed
only on the edges. Therefore it is important
to know the requirements for the edges of
a workpiece. To form “a sharp edge with all
burrs removed”, cut the workpiece to form
a sharp edge and remove all burrs in the deburring
process. For “chamfering” and “round
chamfering”, cutting and the removal of burrs
takes place at the same time.
When cutting the workpiece, secondary
burrs can be formed. Although only slightly,
these burrs formed by chamfering have to be
removed.
Aluminum component with semicircular contour on which the XEBEC
Burrless Chamfering Cutter was tested. The flitter burr after pre-machining
is clearly visible. Even the first test showed the full potential of the new
chamfering cutter, because after the first pass there was no longer any
burr to be seen (clearly visible in the close-up photos, right).
The edge specification of “rounding range”
is becoming popular. Rounding range means
that the shape of the edge is not specified, and
that it is possible to use a chamfering tool, or
modify the edge shape in the deburring process
after chamfering as long as it is within the
range. Therefore, when the edge shape does
not need to have a certain shape for a particular
feature, such a specification allows various
options for edge finish.
no.3, August 2023
29

processes
The mode of action of the patented V-shaped cutting edge is decisive for the secondary burr-free end result. In principle, the
process can be divided and illustrated in three stages: the outer area of the cutting edge shears off the top edge of the material and
pushes the chip towards the center of the bevel. The inner part of the cutter is then used and pushes the chip upwards towards the
center of the bevel. Finally, the chip is sheared off the workpiece at the center of the bevel and the tool leaves the point of contact
with the workpiece. This procedure eliminates burr formation on the chamfered edge. Positioning accuracy is also improved
by a flat tip that is resistant to rounding and chipping that would lead to measurement errors in tool length.
Necessity of burrless chamfering
Burrs are unwanted by-products formed by
cutting tools in the process of shaping the
parts. Ideally no burrs are formed in the cutting
process. Most of the offered products are
tools for the removal of burrs appearing on
workpieces, filling the gap between ideal and
reality.
Since shaping the workpiece edges exactly
is not possible, it is necessary to use a cutting
tool for chamfering/round chamfering on the
workpiece edges. By doing so again burrs will
be formed on the chamfered edges. Therefore
deburring is performed twice. The costs
for performing edge finishing twice is not ignorable.
Even if the process is automated, for
example, to process 200,000 pieces per month! If it takes 5 seconds per piece
to process, it takes 277 hours per month.
Chamfering Features and Properties: chamfering is used to facilitate the
assembly of parts and to prevent assembly problems that can occur due to
overlapping part edges. In addition chamfering can prevent scratches and
injuries during handling. What are the characteristics of roll chamfering?
There are very few exact size requirements, although there are exceptions:
for example, accuracy is unlikely to be affected by tool friction, but burrs
formed during chamfering affect the rolls during chamfering.
From this knowledge, XEBEC Technology was able to develop a burr-free
Chamfering Cutter. The aim is to keep the burr size small; this results to an
extension of the tool life, which is usually defined as being dependent from
the burr size. It also eliminates the need for deburring after chamfering.
If the current machining process includes deburring after chamfering, the
deburring process can be eliminated, or the burr prevention effect can help
to extend the tool life of the deburring tool. As a result, burrless chamfering
can help to reduce idle time of machines, improving the productivity and
reducing the costs.
V-shaped blade mechanism
Most Chamfering Cutters have straight blades. By using a cutter with a
straight blade, poisson burrs which form orthogonally to the tool direction,
can be formed on the upper and lower parts of the chamfered edge.
Poisson burrs are formed because the workpiece material is pushed forward
during cutting, and the material escapes orthogonally. The V-shaped blade
developed by XEBEC is designed to make the plastic flow of the workpiece
go toward the inside of the chamfering range, as to eliminate formations of
poisson burr.
A close-up of the patented cutting geometry
with the V-shaped cutting edges. It took
almost five years to develop this special shape,
which offers clear advantages over straight
cutting edges. Longer tool life, higher feed rates
and no secondary burrs are guaranteed.
If we now look at the test results with the V-shaped blade and the straight
blade when chamfering workpieces made of different material, we can see
that the V-shaped blade has a burr-preventing effect when chamfering different
materials.
For example, when deburring workpieces made of fibrous materials such
as CFRP and woven Bakelite with the straight blade, the fibers remaining on
the workpieces had to be removed manually. On the other hand, when the
V-shaped blade was used to deburr the workpieces, no fibers were left on the
edges and the surface layer was not removed.
30 no.3, August 2023

processes
Another test took place on a quite complex stainless steel component. For experimental purposes, the burr formation was
maximised during the preliminary work – but the burrless chamfering cutter also removed this hefty burr in one pass
without leaving any residue and a uniform chamfer was applied.
Preventing burr formation stabilizes
mass production
A test was conducted to determine the difference
in tool life between the V-shaped cutter
and the straight blade cutter by measuring
the size of the burr. Both cutters were made of
the same material and given the same coating.
The machining parameters were as follows:
workpiece material: stainless steel |
speed: 6000min -1 | feed rate: 1200 mm/min
Results and observations
Tests indicate the burr size is correlated to the cutting distance, when using
either the V-shaped blade or the straight blade cutters.
Regarding the burrs on the upper edges, the difference is not significant
at the beginning of cutting. But as the cutting distance advanced due to the
blade wearing out, the burr size suddenly got bigger with the straight blade.
Whereas with the V-shaped blade cutter the growth of burrs remained moderate.
As a result there was a significant difference in burr size in the end.
Regarding the burrs on the lower edges the difference in using different
blades is significant, even from the beginning of cutting. Under the general
standard of quality inspection, the tool life of the V-shaped blade is twice
as long as that of the straight blade. From the results of several tests, it is
verified that the V-shaped blade has the following effects
■ prevents burr formation on workpieces made of various materials
■ prevents the growth of burrs caused by the friction of the tool
The quality of the workpiece is a target that can be achieved by fulfilling
the requirements. However, in the cutting process, undesirable burrs are
formed on the workpiece edges. Therefore, it is necessary to remove burrs
after cutting to make the workpiece as close to as specified in the drawing. The
appearance of each workpiece can vary when manually deburred. Even when
the workpiece is deburred in an automated process, unwanted patterns or
tool marks can emerge, depending on the used deburring tool.
An overview of the different types of Burrless
Chamfering Cutter. On the far left and lying,
the type 06M with four cutting edges and
high-temperature resistant AlTiCrN coating.
Next to the right, type 06N, also with
four cutting edges but without coating, but
with extremely sharp cutting edges without
rounding. Then the type 03M with stepped
shank, three cutting edges and AlTiCrN
coating and on the far right the type 03N
with stepped shank, three cutting edges
but without coating.
For the customer one of the requirements is the appearance of the workpiece.
But it is not necessary to provide products that are overly excellent in
appearance. However, the products vague in appearance can be regarded as
uncertain in accuracy even when the accuracy is up to the standard. Burrs
are formed on the edges of the workpieces. That means, securing the edge
quality, which is an important matter in appearance inspection, is an important
final touch to finish the product.
XEBEC Technology is a specialist deburring tool manufacturer based in
Japan. XEBEC pioneered the use of ceramic fiber brushes in deburring and
has been helping factories and machining shops automate their deburring
processes since 2002.
further information: www.xebec-tech.com | www.kempf-tools.com
no.3, August 2023
31

processes
Lightweight damper system for use in
lightweight structures
written by
Thomas Götz and Ralf Müllner,
Fraunhofer Institute for Manufacturing Engineering and Automation IPA
Lightweight structures can offer productivity
advantages, especially in highly dynamic applications
such as machining technology, but they are significantly
more susceptible to vibrations than solid structures.
The research project “LeDALe” addresses this
challenge and aims to develop weight-reduced damper
systems for integration into lightweight structures,
which will be tested on the applications chuck and cutting
tool.
In the context of modern, highly automated series production,
machine and plant manufacturers are increasingly confronted
with a trend towards shorter cycle times, greater
diversity of variants and decreasing batch sizes. Meeting
these demands requires the development of highly productive
and flexible machine and plant concepts, which at the same
time must be offered to the customer at a minimum price.
Often these objectives go hand in hand with the need for a
highly dynamic working speed of the machines, which in
turn is significantly related to the weight of moving machine
parts. A mass reduction of these machine parts leads to a
more favourable machine dynamics and thus to an increase
in productivity. Here, the use of modern lightweight materials
and principles can make a decisive contribution and
achieve concrete technological added value at simultaneously
minimized costs. [1]
However, machine structures in lightweight construction
are often significantly more susceptible to vibrations com-
pared to conventional solid construction due to their low
system damping. Particularly in highly dynamic applications
such as metal-cutting machines, these vibrations have
a disruptive effect on the work process during operation. The
results are high noise emissions, poor machining quality or,
in extreme cases, even damage to the machine and its components
due to high vibration amplitudes.
The research project “LeDALe – Lightweight damper system
for use in lightweight structures” addresses this challenge and
aims at the development of weight-reduced damper systems
for integration into lightweight constructions which are to be
put into practice and validated in two common applications
in the area of machinery and plant engineering, the chuck
and cutting tool.
Vibration phenomena in the machining process
In the machining process, dynamic disturbances can occur
in the form of different vibration phenomena (table 1). Basically,
a distinction must be made between self-excited and
[2, 3]
externally excited vibrations.
Externally excited vibrations are due to an external excitation
force, which can occur either impulsively or periodically.
The impulse excitation is caused, for example, by a fast axis
movement or by cutting into material inhomogeneities. The
externally excited vibration after a single excitation is characterised
by the fact that the machine system with its natural
externally excited vibrations
self-excited
vibrations
impulse excitation periodic excitation dynamic instability
cause of
vibration
• cutting into material
inhomogeneity
• fast axis movement
• …
• cutting edge entry during
interrupted cut
• imbalances
• …
• regenerative effect
• noise floor of the
cutting forces
• …
system
response
system response with
natural frequency
system response with
excitation frequency
system response in the range
of a natural frequency
table 1
Types of vibration and their causes according to [2]
32 no. 3, August 2023

processes
frequency is set into vibrations, which decay exponentially
[2, 3]
due to the system damping.
With periodic external excitation, however, the vibrational
system is excited at the excitation frequency. In this context,
examples include cutting engagement impacts during
the milling process in which the machine structure
connected via the milling tool resonates with the periodic
excitation frequency. The closer this excitation frequency is
to the machine’s natural frequency, the higher the amplitudes
of the externally excited vibrations. The amplitudes reach
their maximum when the excitation frequency coincides
with the natural frequency of the machine, which is called
[2, 3]
resonance.
Approaches
In contrast, no external perturbing forces act on the machine
system during the self-excited vibration. Instead, the
vibrations result from the interaction between the cutting
process and the connected machine structure. If, for example,
the machine system is subjected to externally excited
vibrations due to cutting edge entry, the vibration leaves a
ripple on the workpiece surface. This ripple is particularly
pronounced at vibration amplitudes in the resonance frequency
of the machine due to its greater compliance for this
frequency [3] . The chip thickness changes caused by the ripple
in turn induce an increased vibration excitation of the machine
in the natural frequency during chip removal by the
subsequent tool cutting edge, which is referred to as the regenerative
effect (figure 1). The self-excited vibration is thus
a consequence of the surface ripple generated by the external
[2, 3]
excitation, which leads to greater process instability.
to reduce vibrations
Various methods are available to reduce vibration phenomena
in the machining process.
This includes, among other things, the decoupling of the
excitation by the use of elastic intermediate components, the
so-called insulating elements. However, decoupling close to
the excitation in the force flow of the machine structure, e.g.
at the tool holder or workpiece clamping device, is usually
associated with high resilience and therefore can only be
[2, 5]
implemented with great restrictions.
Another approach aims at changing the excitation frequency
by selecting suitable cutting parameters so that it is
no longer in the range of a dominant resonance frequency of
the machine structure. However, this measure requires a certain
amount of experience on the part of the operating personnel
and often affects productivity, as it is usually necessary
to deviate from the optimum process parameters. Thus,
either the process time is extended when the parameters are
reduced or the tool life is shortened when the parameters are
[5, 6]
increased.
The withdrawal of the vibration energy can also be achieved
via the principle of material damping. In this case, vibration
energy can be converted into heat through the use of viscoelastic
materials. Physical causes of this energy dissipation
are, for example, sliding processes or microplastic deformations
in the damping material. Currently, there are concepts
of toolholders with integrated viscous dampers which have
up to 90 % less dynamic compliance compared to undamped
figure 1
Regenerative self-excited vibrations
using the example of grooving [4]
first impulsive excitation
cutting a ripple on the
workpiece
incision in the waviness
after a workpiece rotation
upswing of the process
(chatter vibrations)
no. 3, August 2023
33

processes
figure 2
left:
Spring-mass system of vibration absorber and auxiliary mass damper [7]
right:
Cutting tool system with auxiliary mass damper [8]
toolholders. However, these concepts require an increased
static compliance of the tool clamping to allow higher deformations
of the viscous dampers. The increased static compliance
of the tool holder, however, results in a higher tool displacement
and thus leads to dimensional and shape errors. [6]
Principle of vibration absorber
Another important method of damping vibrations is the
principle of vibration absorber (figure 2, left), whereby the
vibration is compensated for by means of additional masses.
If a harmonic excitation with a certain frequency acts on
a vibrating system, the system will vibrate with the same
frequency. If an absorber mass is coupled to this system by
means of a spring, the absorber executes oscillating movements
in the opposite direction to the excitation, thereby
withdrawing oscillation energy from the main system for its
own oscillating movement. Provided, the absorber’s natural
frequency is optimally tuned to the excitation frequency
to be eliminated, the vibrations of the main system mass
can be completely stopped, whereby two new pronounced
resonance points are formed. However, this behaviour only
occurs with ideal, i.e. pure spring coupling. Under real conditions,
the spring-mass oscillator also has a damping component
in the coupling and is called an auxiliary mass damper
(figure 2, left). Although the vibration to be eliminated is not
completely suppressed here, the new resonance points do not
form as strongly.
Contact
Auxiliary mass dampers are already being used successfully
by some cutting tool manufacturers for damping overlong
cutting tools (figure 2, right) as well as long, slim extensions
with large length-to-diameter
[2, 5, 7, 8]
ratios.
surface damping and
hydraulic expansion chuck
An alternative to vibration absorbers is the contact surface
damping, in which the vibration energy is converted into heat
via a friction process (figure 3, left). In a first implementation
of this principle on tool holders for long projecting rotating
cutting tools, friction bars are used to reduce vibrations (figure
3, right). A deformation of the basic structure leads to a
relative movement between the prestressed friction bars and
[6, 9]
the basic structure, whereby a friction work is realised.
Another application example in the field of contact surface
damping is the hydraulic expansion chuck. In this system,
by turning a clamping screw in the pressure chamber of the
hydraulic system, a pressure is generated which leads to the
elastic deformation of the expansion sleeve. The cutting tool
located in the clamping sleeve is thereby clamped forcefully
(clamping connection). In the process, the relative movements
in the contact surfaces between cutting tool and
clamp ing sleeve lead to friction, which contributes to vibration
damping of the system. [10]
All previously realized designs for contact surface damping
are exclusively available in solid designs in order to support
the normal force (clamping force) required to build up
the frictional force.
Summary and outlook
With regard to the state of the art, it can be concluded that
many successful approaches to increase damping in cutting
tools and clamping devices already exist, which, however,
require a high degree of competence in process control or are
not designed for lightweight construction.
34 no.3, August 2023

processes
F = applied force
F R = frictional force
F N = normal force
figure 3
left: Principle of friction
right: Tool holder based on friction strip dampers [9]
For the development of low-mass damper systems, the
principle of the friction damper appears to be principally
well suited. In order to achieve the highest possible degree
of lightweight construction, this damping approach is to be
realised within the framework of “LeDALe” using a combination
of various lightweight construction principles and manufacturing
technologies. These include lightweight design,
which aims to minimise weight by optimising shape and topology,
whereby a constant stiffness of the damper structure
is achieved with low material input. Another option is lightweight
manufacturing, in which weight-saving potentials are
realised through manufacturing and production processes,
such as additive manufacturing methods. The third approach
is lightweight material construction, which enables weight
reduction through the use of lightweight materials such as
fiber composites.
Acknowledgements
The LeDALe research project is funded by the Baden-
Württemberg Ministry of Economics, Labour and Tourism
(WM BW) as part of the “Invest BW” funding programme
and is supervised by the VDI/VDE-IT project management
organisation. The authors would like to thank the WM BW
for the funding granted. In addition, the authors would
like to thank the project management organisation and all
project staff involved for their support.
Literature
[1]
Hansmersmann, A.; Birenbaum, C.; Burkhardt, J.;
Schneider, M.; Stroka, M. (2016)
Leichtbau im Maschinen-, Anlagen und Gerätebau:
Herausforderungen - Potenziale - Mehrwerte - Beispiele.
Handbuch für den praktischen Gebrauch.
Internet: https://www.ipa.fraunhofer.de/content/dam/
ipa/de/documents/Kompetenzen/Leichtbautechnologien/
IPA_Leichtbaustudie_Leichtbau_im_Maschinenbau.pdf
[2]
Baur, M. (2013)
Aktives Dämpfungssystem zur Ratterunterdrückung
an spanenden Werkzeugmaschinen.
Entwurf und experimentelle Validierung
dissertation, Technische Universität München
[3]
Weck, M.; Brecher, C. (2006)
Werkzeugmaschinen 5. Messtechnische Untersuchung
und Beurteilung, dynamische Stabilität
Berlin
[4]
Brecher, C.; Kiesewetter, C.; Kampka, M.; Epple A. (2016)
Prozess-Maschine-Interaktion beim Verzahnungshonen
in: Zeitschrift für wirtschaftlichen Fabrikbetrieb,
volume 111, n° 11, pp. 723 - 726
[5]
Baron, J. (2000)
Untersuchungen zur Auslegung und zum
Betriebsverhalten eines fliehkraftgesteuerten
frequenzvariablen Drehschwingungstilgers
dissertation, university of Hanover
6]
Teige, C.
Entwicklung gedämpfter Werkzeugaufnahmen für
lang auskragende rotierende Werkzeuge
[7]
Tönshoff, K. (1995)
Werkzeugmaschinen
Grundlagen. Berlin
[8]
aufgerufen am 08.12.2021
Schwingungstilger verbessert Qualität
Internet: https://industrieanzeiger.industrie.de/technik/
produkte/schwingungstilger-verbessert-qualitaet/
[9]
aufgerufen am 08.12.2021
Entwicklung gedämpfter Werkzeugaufnahmen für
lang auskragende, rotierende Werkzeuge
Internet: https://www.ifw.uni-hannover.de/en/forschung/
beendete-projekte/research-projects/projects/
development-of-damped-tool-holders-for-longcantilever-rotating-tools
[10]
Fleischer, J.; Schulze, V.; Zanger, F.; Leberle, U.;
Boev, N.; Spohrer, A. (2014)
Spanntechnikvergleich bei der Hochleistungszerspanung.
Hydrodehnspannfutter verbessern Werkzeugstandzeit,
Qualität und Produktivität
in: VDI-Z, August
further information: www.ipa.fraunhofer.de
no.3, August 2023
35

processes
Digital transformation in tooth machining
Time-consuming and costly operations were the
trigger for KAPP NILES to introduce digitalisation
into its machining and support processes.
Particular emphasis was placed on local integration,
but at the same time on the possibility of interfaces in
customer systems. This ensures easy installation and
integration into the existing Industry 4.0 landscape.
With the innovative software platform KN assist the
company has succeeded in finding a practical solution.
Take the set-up process to a new level
Set-up processes are time-consuming and involve the risk of
errors. Since tooling is often used in a multilayered manner,
tracking of the machined workpieces or the clamping cycles
is difficult.
The Kapp Niles Tool Management with guided changeover
sequences at the plant guides the employee step by step
through the set-up process. Within the sequences, the query
for identification takes place. The machine recognises whether
the component is correct for the grinding project, so that the
geometric and process-relevant information is transmitted
to the control system. The KN extender displays all relevant
data of the stored components in a local database outside the
machine (see figure 1).
The use and quality of tooling can be better planned via
stored data, such as clamping and dressing cycles.
figure 1
KN extender manages component inventory
36 no.3, August 2023

processes
figure 2
Dashboard views
Transparency in production
Together with its customers, Kapp Niles has sought a way to
transparently present the Overall Equipment Effectiveness
(OEE) key figures on the machine and on mobile terminals.
The aim is to visualise the relevant KPIs (Key Performance
Indicators) clearly and easily.
With the Kapp Niles Production Monitoring System designed
in this way, all connected machines can be displayed
in a dashboard. Two views can be selected (see figure 2).
The machine overview shows the status of a machine. The
individual machine view displays monitored status values,
OEE key figures, relevant production data and the number
of workpieces processed. The job history gives an overview
of the most used grinding projects. The tooling dashboard
is used in conjunction with the tool management system to
visualise information about the tooling currently in use.
The system also provides an overview of all pending service
requests. New inquiries can also be triggered directly.
André Wetz, product manager at Kapp Niles, describes
further advantages of the Production Monitoring System.
“OEE key figures become easy to access and visualise. The
optimized presentation of the KPIs and the most frequently
used grinding projects specifically show potential in the
production process and environment. The device-independent
access to all relevant production data enables a transparent
display at any time and from anywhere. Reaction times
can thereby be minimized. Optimized communication leads
to faster problem resolution and thus to shorter machine
downtimes.”
Real-time monitoring of the machining process
In order to meet the ever increasing quality requirements
on the component and a high productivity, Kapp Niles has
been looking for a solution for monitoring the grinding and
dressing process. Here too, the company was in close contact
with its customers in order to detect and avoid abnormalities
already in the process. This avoids an expensive 100 % test
afterwards.
The Monitoring System analyses the grinding and dressing
process. The tool state is monitored and an evaluation of ripples
or orders on the component is carried out. Based on the
analysed data, the machining process is determined and visualized
at the HMI. Through adjustable limits, messages indicating
deviations are issued at an early stage. An interface
offers the possibility of providing data via a partial tracing to
each manufactured workpiece. Data outside the machine can
also be analysed in detail via export functions (see figure 3).
Andreas Paatz, head of division service and tools at Kapp
Niles, explains: “This system ensures a comprehensive examination
of relevant features during the grinding and dressing
process. As a result, errors or trends can be detected at an early
stage and scrap and reworking percentage can be reduced. By
monitoring the machining process, conclusions can also be
drawn about the condition of the machine. A further advantage
is that a removal of noisy workpieces after the machining
process is made possible. By means of partial tracing, it is
possible to detect critical workpieces also retroactively. Since
the number of workpieces to be subsequently measured can
be reduced, time and cost savings are achieved.”
figure 3
Export functions facilitate the analysis of machine data
no.3, August 2023
37

processes
figure 4
Powerful IPC is used for monitoring
From prevention to prediction
If an unplanned machine shutdown occurs it can have a
large impact on various factors, such as productivity and on
the adherence to deadlines, depending on the cause, and ultimately
entail additional costs. The Condition Monitoring
System monitors the wear condition of the linear and rotary
axes of the processing machine. By means of specific reference
runs, the condition is recorded during operation of the
machine. The degree of wear of the axes is visually shown
on the HMI of the machine. In addition to a forecast of the
service life, pre-set limits are used to output trends on the
machine. Interfaces for the transmission of relevant data to
further customer-specific production systems are available.
Furthermore the data can be supplied to each manufactured
workpiece via a partial tracing. In analogy to the process
monitoring system, the machine is equipped with additional
sensors and a powerful IPC for evaluating the recorded data
for monitoring the axes (see figure 4).
Andreas Paatz: “The aim is to significantly reduce unplanned
machine downtimes. This allows better planning of maintenance
intervals and prevents unnecessary or premature
replacement of machine components. This is due to the fact
that fewer wear parts have to be kept in stock and can be ordered
on a condition-based basis. The trend in modern production
plants is towards condition-oriented maintenance
and repair. Kapp Niles offers a powerful product here.”
Make maintenance transparent
Unforeseen maintenance work makes life difficult. Unpredictable
production downtime can lead to reduced productivity
and increased costs. If maintenance is necessary, missing
information leads to additional expenditure.
The Maintenance Manager displays all maintenance plans
and instructions in digital form. The database provides complete
maintenance management with triggers, consumables,
time expenditures, responsibilities and priorities. This enables
usage-based maintenance. A traffic light function indicates
when maintenance is due. All activities carried out are
stored in the asset archive.
This archive (see figure 5) is used to support the planning of
maintenance processes.
figure 5
Planning tool for maintenance processes
further information: www.kapp-niles.com
38 no.3, August 2023

processes
Next generation CNC control
The new CNC control by Okuma: the OSP-P500 raises production
to the next level. Customers of the worldwide known manufacturer of
CNC machine tools will benefit from the highest productivity and precision
with special user-friendliness and energy efficiency. The smart
machine control also includes special safety features to protect against
cyber attacks.
An increasing shortage of
skilled workers, growing requirements
for climate-neutral
production and ever more
flexible, multi-variant production
programmes are causing
a sharp rise in the demand for
automated, energy-saving production
processes. 60 years after
the first launch of OSP control,
Okuma is announcing a
revolutionary innovation as the
answer to current and future
challenges.
5th Leading Trade
Fair for Deburring
Technologies and
Precision Surfaces
10 – 12 October 2023
Trade Fair Center
Karlsruhe, Germany
Efficient machining by everyone
The new OSP-P500 control is equipped with the “Digital Twin” to speed up the
production processes and reduce preparation times. It facilitates high-precision
simulations of the machining processes: with “Digital Twin on Machine” this
simulation takes place on the machine itself, so that machining can be started
immediately afterwards. Simulation can also be done with “Digital Twin on
PC” on a computer to prevent downtimes, allowing the machine to be used for
other machining processes. Even inexperienced users benefit from all the advantages
of the CNC control thanks to the exceptionally user-friendly interface.
The “Smart OSP Operation” function simplifies handling and provides automatic
guidance through all the necessary steps, meaning that people without
any prior experience can learn how to machine a workpiece in a single day.
The OSP-P500 is also ideally equipped for high-speed machining with high
surface quality: thanks to “Smart Control”, it has twice the computing power
of conventional machine controls. This significantly shortens reaction times so
that the cycle times can be reduced by up to 15 %.
Smart technology for greater energy efficiency
Thanks to the integrated “Eco Suite Plus”, the new OSP-P500 meets all customer
requirements of reducing the power consumption. The smart features record
and analyses every operating status and CO₂ emissions, switch to energy-saving
idling if required and automatically adjust peripherals, such as the chip conveyor
or suction. In future Okuma will gradually launch a range of new Green
Smart Machines. These intelligent machine tools are particularly designed for
the reduction of CO₂ emissions with reduced energy consumption, while still
ensuring the highest quality. The OSP-P500 is also part of the package.
Knowledge
Transfer
& Solutions
to produce components
burr-free, precise and
clean.
New machine design for 5-axis machining centers and
multitasking machines
The 5-axis machining centers of the MU-V series and the multitasking machines
of the MULTUS series will be equipped with the new machine control. The
first machines with the new control and design will be delivered to customers
in Europe at the end of 2023.
further information: www.okuma.eu
© gonin | Fotolia.com
deburring-expo.com
no.3, August 2023 39
23-0025707 © w-id.de

machining center
From watchmaker to precision manufacturer
Opening new industries with a
Kern Micro HD around the globe
High precision manufacturing is the basis of every
successful watchmaker. So why not use this knowledge
for other industries? That’s what Nicholas Hacko
thought. After founding “Nicholas Hacko Watchmaker”
(NHW) in Sydney in 2011, he launched another company,
NH Micro, in 2020. Here he works for many parallel
precision industries – from medical technology to
aerospace. Investments in the best five-axis milling
technology – most recently in a Kern Micro HD – were
decisive for his success.
Nicholas and Josh Hacko are thrilled about their
Kern Micro HD: “With the experience we have gained so far,
we believe that this manufacturing center will pay for itself
in less than five years, despite the high investment costs”
Watchmaking and high-precision engineering are in the
Hacko’s blood. When Nicholas Hacko emigrated from Europe
to Australia in 1992, he was already working in the industry
as a third-generation watchmaker. Since his son Josh was also
learning the profession, he decided to start his own brand in
2011 – NHW. The focus of NHW was to become an independent
watchmaker in Australia, manufacturing high quality
timepieces.
Being aware that the highest quality requires the highest
precision – and that this cannot be achieved without the best
manufacturing technology – the small company invested in a
used Kern Pyramid Nano five-axis machining center in 2017.
Nicholas Hacko remembers: “It was a big investment for us.
But it paid off extremely quickly. The machine reliably mills
tiny parts like gears, bridges, mainplates, levers and other
small parts with the highest level of accuracy, with very high
efficiency.”
The parts from NH Micro require manufacturing accuracies
in the micrometer range and surfaces up to Ra ≤15 nm
Internal watch production grew quickly and within 5 years
NHW had released 5 models. This rapid growth begged the
question: which other industries – beside the watchmaking
industry – require unique parts manufactured with such high
precision? Nicholas and Josh Hacko concluded that medical
technology and aerospace companies, for example, would
have great demands as growing markets. So it would be obvious
to use existing knowledge and capacities and expand the
field. Could, should, would. It was necessary to overcome the
subjunctive and act.
40 no. 3, August 2023

machining center
Rocket start with his job shop
That’s exactly what the Hacko’s did for the first time at the
end of 2018. “Our first non-watchmaking-industry part was
for a Formula 1 racing team,” says Nicholas Hacko. “We were
commissioned to produce sample parts. These were never
used in serial production, but our client was satisfied and that
was an eye-opener for us. We suddenly saw the enormous
field of precision parts applications.”
Orders from medical technology, mold-making and scientific
instrumentation companies followed a short time later,
and the business picked up speed. The watchmaker founded
a second company called NH Micro in 2020. News of the
high quality of Hacko precision parts spread quickly, causing
sales to double from 2020 to 2021, even despite the Covid
crisis. Accordingly the capacities of the Kern Pyramid Nano
soon reached its limits. Nicholas Hacko asked his Kern advisor,
Udo Reinwald, Kern Asia pacific director at the beginning
of 2021 which solution he would recommend. With the
rapid development and potential future of the two NH operations
in mind, he suggested the world’s best five-axis machine
for high-precision machining, the Kern Micro HD.
Investing in the world’s best five-axis machine
for high precision
Nicholas Hacko was just as enthusiastic about this machining
center as his son Josh. They recognized the potential and
made a rather conservative ROI calculation. Josh Hacko explains:
“It was a big investment for our small company with
nine employees. However, seeing the potential that would be
enabled with the new machining center, it should have paid
for itself in around five years, our decision was quickly made,
and we ordered the Kern Micro HD.”
The machine was put into operation in March 2022. With
full order books the Kern Micro HD now runs every day –
without any problems. And their range of customers keeps
growing. To name just a few examples: in addition to prototypes
and small series’ of up to 500 pieces for medical technology,
orders for opto-mechanical and microfluidic components
are increasing, as well as for rocket propulsion nozzles,
fiber optic connectors and dosing pump components.
“There hasn’t been a part for which our Micro HD hasn't
achieved the required accuracy,” says Nicholas Hacko happily,
explaining the main requirements placed on his operation:
“For our internal watch production, manufacturing accuracies
of around five micrometers is quite common. But every
now and then there are parts where bore positions and diameters
with tolerances down to +/- 2 µm must be maintained.”
This is no problem for the Kern Micro HD. If required, it also
achieves precision of less than 1 µm in serial production.
When it comes to surface quality, NHW and NH Micro
also have very high standards. When processing different
steels you need Ra values of ≤ 20 nm and, in some cases,
Ra ≤ 15 nm for non-ferrous materials. Hacko says: “We achieve
this reliably. However, I believe that even better values would
be possible if required.” He is right, as Reinwald confirms:
“With the Micro HD we can also achieve Ra values in the
single-digit nanometer range.
The Kern Micro HD is easy to operate and has extremely fast
linear motors, resulting in very high processing speeds
NH Micro, Sydney (Australia), …
…was founded in 2020 by Nicholas Hacko. He started
his own watchmaking company in 2011 (NHW), which
has been producing up to 80 % of its watch components
in-house since 2016. In 2018 Hacko began to work as a
contract manufacturer, supplying precision parts to
companies in other industries. Today the two small
companies NHW and NH Micro employ nine people.
no. 3, August 2023
41

machining center
Shown here is an internal automation package within the tool changing cabinet;
up to 210 slots are available in the tool changer of the Kern Micro HD, enabling NH Micro
to manufacture a wide range of different precision parts without having to change tools
There is almost no temperature influence
There are a few technological highlights, unique even for a
precision machining center, that are decisive for accuracy.
The Micro HD used by NH Micro has a sophisticated temperature
management system that is unique to the market.
With this special solution, the Kern Micro HD remains within
a temperature range of +/- 50 mK even under extreme
conditions. This is crucial because – according to recent research
– temperature influences are responsible for around
70 % of all accuracy errors in the high-precision area.
Another advantage is in the large-scale and actively temperature-controlled
linear motors. Compared to ball screw
drives, they bring clear advantages in terms of dynamics
and control accuracy and achieve rapid traverse speeds of
60 m/min. Nicholas Hacko says: “This keeps our non-productive
times very low. We are working much more efficiently
than would be possible with other machines.”
The owners of NH Micro – Nicholas and Josh Hacko – have
precision in their blood, but they also regularly prove this
with high-quality measurement technology
The many technical refinements of the Kern Micro HD
and their high quality, together with their ever-growing
order book, make the Hacko’s optimistic for the future. The
two companies are growing steadily, so that after 2021 their
sales doubled again in 2022 – despite the difficult global
situation. In addition to the Australian market orders from
Europe and the USA are now also increasing. Accordingly
Nicholas Hacko is even more relaxed about his latest investment
today: “Based on the experience we have gained, I believe
that it will take us less than five years for the Kern Micro
HD to pay for itself.”
further information: www.kern-microtechnik.com
42 no. 3, August 2023

A partnership for an automated future
components
At automatica 2023 (Munich) SCHUNK exhibited
smart new developments that enable handling tasks to
be solved transparently, flexibly and reliably.
Making its customers’ processes understandable, simple and
efficient is the declared goal of automation specialist SCHUNK.
Data transparency plays an important role here. It enables reliable
processes and provides the basis for resource-efficient
planning, zero-defect production and energy efficiency. The
digitalization of components and processes go hand-in-hand
with sustainable manufacturing. It was shown how digital solutions
lead to greater efficiency and lower resource consumption
with practical examples from automated production in a
wide field of applications.
In focus: transparent processes
SCHUNK showed a whole range of new products that contribute
to a boost in efficiency. Among other things the PPD
positioning unit made its debut, enabling more complex motion
sequences in pneumatic handling. In conjunction with
pneumatic grippers, gripper fingers can be controlled flexibly
and with high precision, and gripping force and speed can be
regulated. Required application parameters for defined gripper
series are already stored on the unit – this saves time during
commissioning. Combined with the power ful, pneumatic
universal gripper PGL-plus-P with an extra-long stroke, versatile
handling tasks can be realized even in demanding environments,
from machine loading to highly sensitive cleanroom
applications. As the first in the world the company offers
the pneumatic gripper with a certified, secure GripGuard
gripping force maintenance. It has an already integrated IO-
Link sensor system that enables position sensing of the gripper
fingers and thus saves on external sensors.
Flexible from batch size 1
Two new electric grippers set standards in terms of flexibi lity,
interface diversity, and process reliability: the smart universal
gripper EGU shows its strengths to the full in multi-variant
machine loading, even under harsh conditions. With its large
stroke and integrated gripping force retention it is able to
reliably load and unload raw and finished parts of different
sizes. It can be freely networked. The integrated gripping
force maintenance and a StrongGrip mode for increased gripping
force makes it an all-rounder for all handling tasks. Its
counterpart for handling delicate, fragile parts in cleanroom
areas is the smart EGK gripper for small components. With
its SoftGrip mode it masters demanding and varied handling
tasks in the laboratory industry or electronics manufacturing.
Both grippers are offered with extensive function modules
and commissioning plug-ins.
Easy entry into intelligent handling
For handling individual objects the user-friendly 2D Grasping
Kit has been developed, randomly arranged on a single
level, which makes it much easier to get started with automated
object handling. The core of this intelligent system is
SCHUNK presented a new generation of linear direct drive axes
with the SLD series and therefore ensures short cycle times
and more productivity
the in-house developed AI software, which is pre-installed
on SCHUNK’s own industrial PC (SVC). Since the market
launch in 2022 the automation expert has further optimized
the software and simplified the teaching and labeling of components.
This coordinated complete package of hardware, soft
ware and service comes from one source and can be used for
all robots.
Power through direct drive
The first time presented dynamic linear direct axes SLD can
handle higher load capacities, due to the profiled rail guide
and compact design, having a long service life. With heavyduty
axes equipped with electric linear direct drive, users
achieve increased productivity in high-speed assembly and
handling processes due to the short cycle times.
The new flat ERT rotary units are also equipped with direct
drive and offer a wide range of measuring system interfaces
such as the HIPERFACE DSL® digital real-time interface and
an electric holding brake. The unit can be used as a rotary
table for components, assembly groups and tools, or as a rotary
module in gantry solutions, as a rotary indexing table or a
precise positioning module.
Your partner when switching over to automation
In order to successfully counter the shortage of skilled workers
and pressure for efficiency and to accompany the change
to digital, more sustainable manufacturing processes, the
application expert offers a variety of automation approaches
from a single source. The company demonstrates automation
solutions for new, easy-to-integrate manufacturing
and assembly processes that meet the requirements for precision,
dynamics and reliability in different industries such as
e-mobility and life science.
further information: www.schunk.com
no. 3, August 2023
43

components
When precision is of the essence
The CNC dividing heads of the HOFMANN RWNC
series have been known for their high precision since
they were first launched. This is made possible through
Rodriguez components that are used in the bearings of
the dividing spindles. With new applications requiring
even greater precision, the partners jointly developed
an alternative solution: special high-precision bearings
can meet the ambitious requirements.
Hofmann is a well-known supplier of key components for the
machine tool industry. The company manufactures all major
components for dividing and rotary movements in its own
modern manufacturing facilities. It focuses on tailor-made
solutions that are impossible to achieve with standard solutions
from other manufacturers. In addition to dividing units
and rotary tables, the product range also comprises a wide
range of coordinated accessories, including tailstocks and
counter-supports for bracing long workpieces.
Included in this range is the RWNC single-axis NC dividing
unit, which is suitable for use with both vertical and horizontal
rotary axes. The standard tip heights of the RWNC series
are 75, 100, 125, 160, 220, 300, 380 and 400 mm. Special
tip heights can be achieved by using bases or adapted housings.
The hydraulic clamp of the dividing spindle enables
high machining forces to be applied. It is also possible to use
indirect or direct position measuring systems.
Excellent radial and axial run-out
as a unique selling proposition
“The CNC dividers in the HOFMANN RWNC series are primarily
distinguished by their mature, robust and stable design”,
says Timo Conzelmann, head of design at Hofmann.
“Coupled with exceedingly high accuracy values, the customer
receives a reliable solution that is individually tailored
to the respective application scenario.” The dividing heads
are used primarily as a 4th axis on machining stations and
on engraving, grinding or measuring machines. They feature
a stable, vibration-free design and also stand the test of rough
working conditions thanks to their robust construction.
The Rodriguez rotary table bearings (RTB) are now
also available in an HSA version
image: Unitec | Rodriguez GmbH
The Rodriguez components used in the bearings of the
dividing spindles all contribute to the high precision of the
CNC dividing units
image: Werkzeugsysteme Müller GmbH
The eccentrically adjustable worm drive of the dividing
heads consists of a case-carburised worm shaft and a worm
gear made of an extremely low-wear bronze alloy. Coupled
with a high performance lubricant, it runs with very little
fric tion and backlash, thus also consuming very little power
compared to torque drives. “What is particularly noteworthy
is the high level of accuracy”, emphasises Timo Conzelmann.
“The outstanding radial and axial runout on the dividing
spindle is due in part to the Rodriguez bearings.”
New requirements for accuracy
Up to now the drives of the dividing heads used a fourpoint
Rodriguez bearing as the radial thrust bearing, whereas
the tilting moment was supported on a radial ball bearing.
This combination has proven itself over many years – but
now there was a wish to achieve even higher levels of accuracy,
which could not be achieved using the previous bearing
arrangement.
“Our dividing heads are used, among other things, for
thread measurement in measuring machines”, explains Timo
Conzelmann. “The workpiece is clamped between fixed tips
in the dividing unit and tailstock.” For this the dividing unit
is equipped with an optional dividing spindle with an Mk-2
Morse taper. This application requires an elevated radial and
axial run-out in the Morse taper of less than 0.006 mm – for
comparison: Until now a maximum of 0.01 mm was the rule.
In concrete terms, the specification given to Rodriguez was:
the new version would have to achieve a runout of 0.005 mm
in the Morse taper and on the gauging mandrel and a runout
of 0.0025 mm on the dividing spindle face.
Precise, very precise, high-precision bearings
“In close cooperation with the customer we developed a new
solution tailored to the new requirement profile”, explains
Ulrich Schroth, key account manager for VAP at Rodriguez.
44 no. 3, August 2023

components
“The dividing spindle is now supported in a spindle bearing
arranged in an O arrangement in each case and held in place
with a shaft nut.” The customer grinds the inside of the Mk-2
Morse taper of the dividing spindle in its assembled state on
the grinding machine driven by the dividing unit itself. This
puts accuracy within this range.
The dividing heads now use high-precision bearings from
SKF’s “Super Precision Bearings” series, which Rodriguez has
had in its range since 2020. These high-precision (axial) angular
contact ball and cylindrical roller bearings are specially
designed for the tough requirements of machine tools. They
not only support high rotational speeds and payloads, but
also run as stiffly and extremely accurately as possible and,
last but not least, generate little heat and low levels of noise
and vibration. They also have an impressively long service
life, long maintenance intervals and low energy consumption.
Large range of bearings for the machine tool sector
“The high-precision bearings enable original equipment
manufacturers and end users to further optimise the parameters
of their systems and applications”, says Ulrich Schroth.
“This can be very well demonstrated by the present application”.
In the field of machine tools, the bearing arrangement
of spindles and rotary or indexing tables is important for
optimum force absorption and transmission. Thanks to its
comprehensive range of precision rolling bearings, Rodriguez
can optimally meet all requirements.
High precision in use is usually of utmost importance.
Bearing manufacturers are still making improvements in
this respect. A further example of this are the Rodriguez rotary
table bearing series (RTB), which have been available in
a new version for some time. These high-precision solutions
are particularly suitable for positioning rotary or indexing tables
in machining stations. Now they are also available in an
HSA version, which offers impressive stiffness, requires 20 %
less starting and running torque and offers a 20 % increase in
speed. Users also benefit from up to 70 % more moment rigidity
and load capacity (both axial and radial). These significant
improvements were achieved, among other things, through
re-dimensioning of the RTB bearings by the manufacturer
and an optimised production process.
Breaking new ground
together with the customer
“In this case improved models and new software enabled a
more accurate calculation”, concludes Ulrich Schroth. “Tests
and developments in cooperation with selected customers
also generated valuable experience and greater expertise in
this field. I think that especially the latter is extremely important,
beyond any trends: working out solutions that the market
really needs, jointly with the customer.” This has always
been Rodriguez’s philosophy – which is also reflected in the
new version of the HOFMANN dividing head.
further information: www.rodriguez.de
Hello
visitors!
Welcome to the
world’s leading trade
fair for production
technology.
no.3, August 2023
45

components
New CAM software will drastically improve the way
manufacturers operate their Laser machines
GF Machining Solutions has launched a new version
of a computer-aided manufacturing (CAM) software,
LaserCAM, part of the LaserSUITE360 software package.
At the EPHJ tradeshow in Geneva (Switzerland), GF Machining
Solutions has introduced the new advanced software LaserCAM.
LaserCAM, included in the LaserSUITE360 1.13.0
software package, offers operators a completely new user
inter face for creating and editing laser engraving and decoration
designs easily. It provides improved calculation speeds,
reducing the time required for programming and setup,
Example of a micromachining application shown in LaserCAM
and enables manufacturers to respond to changing production
needs quickly and get their products faster to market.
It is specifically designed for laser engraving, micromachining
and decoration operations, with over a decade of experience
in the field and promising to drastically improve the way
manufacturers operate their laser machines. This will allow
manufacturers in watchmaking who have been hesitant to do
so to adopt laser machining for their applications.
In addition to its existing engraving tools, LaserCAM includes
unique features such as 3D finishing, blasting and
watchmaking decoration functions, allowing manufacturers
to create intricate and precise designs. The software has been
developed with a novel modular architecture, which is a significant
leap forward in user-friendliness. GF Machining
Solutions will be able to expand the features in the coming
versions, aiming to consolidate its leading position in micro
cavity, semiconductor and hard material machining as well as
watchmaking applications. LaserCAM is compatible with the
entire range of GF Machining Solutions’ Laser ablation machines
to meet the specific needs of every manufacturer.
further information: www.gfms.com
Strong all-in solution for efficient quality inspections
The new ZEISS VoluMax 9 titan is compact design
and powerful technology combined. The system comes
with 450 kV, thus enabling reliable and consistent detection
of defects in both large, high-density parts and
complex multi-material assemblies with a size of up to
590 x 700 mm.
Dense parts are inspected at high resolution courtesy of
1,500 W and a 3k-detector. Therefore ZEISS VoluMax 9 titan
is suited for a broad range of applications that put all sorts
of demands on efficiency and quality. Among the most common
applications are battery modules and stators as well
as turbine blades or electronic parts.
ZEISS VoluMax 9 titan reliable high-resolution detection
of defects in multi-material parts
Volume Inspect – comprehensive workflow
with a single software
The connection of the new ZEISS VoluMax 9 titan to the
ZEISS Quality Suite is one of the major advantages of the system.
All steps in the inspection of parts – from operating the
CT to inspecting high-resolution 3D volume data sets to creating
and sharing the final report – can be performed with
the Volume Inspect software solution. Next to maximum
ease of use, the software integration offers access to various
add-ons. For example, scanning processes can be optimized
even further with ZEISS Automated Defect Detection
(ZADD), an optional software solution for the AI-based,
automated detection of defects.
ZEISS VoluMax 9 titan – compact design and
high performance combined
ZEISS VoluMax 9 titan is extremely compact with its small
installation area of no more than 2,750 x 2,350 x 1,750 mm. So
the CT is ideally suited for installation in every quality laboratory
or in close proximity to the production line. The integrated
control panel and the improved axis system for easy
loading ensures a high degree of flexibility and efficient operation
in the smallest of spaces. ZEISS guarantees a long life
cycle and a low maintenance level. Qualified service teams in
more than two dozen countries stand ready for help.
further information: www.zeiss.com
46 no. 3, August 2023

EMO
Digitalization and sustainability
More than 1,750 exhibitors from 42
countries are currently expected at EMO
Hannover 2023. They will present the entire
spectrum of production technology.
Major points of interest include machining
centers and lathes, cutting tools and
clamping devices, measuring equipment
and control systems. “The breadth of the
technical offerings is unparalleled at the
international trade fair for production
technology,” emphasized Markus Heering,
executive director of the VDW.
The event highlights the challenges that exist
in production: greater efficiency, more flexibility,
better quality, increased accuracy, the
integration of AI, comprehensive factory-wide
networking and much more besides.
EMO Hannover is offering various joint
stands aimed at drawing attention to specific
trend topics: additive manufacturing, connectivity,
cobots and sustainability in production.
“In particular, latest developments such as
those showcased in the sustainability in production
area are attracting a lot of interest, as
exhibitors are keen to reposition themselves
in this field,” reported Wilfried Schäfer, executive
director of the VDW. Research institutes
will also feature prominently on the stand, using
it to present their sustainability projects.
Trend forum for the future of production technology
As the world’s leading trade fair for production technology, EMO Hannover
aims to cover all the important topics relating to the industrial value chain,
to present the current state of the art and to highlight possible scenarios for
future development. “In addition to the aforementioned topics, a further
focus will be on the recruitment of skilled workers on the special training
stand.”
The special umati stand will feature a major live demonstration aimed at
showcasing the latest developments in the connectivity initiative for the mechanical
and plant engineering industry as a basis for effective networking
within and between factories. Finally, the startup area will be promoting
pioneering collaboration with young companies, said Schäfer, describing two
further examples.
The joint stands will be complemented by two forums in halls 9 and 16
of the Hannover exhibition center. They provide a platform for exhibitors’
presentations on technology topics and for in-depth presentations on special
future insights topics.
The program includes a conference on business opportunities in the Indian
market, and two half-days entitled “New digital work – opportunity or
disenfranchisement?” Both go into greater depth on individual aspects of the
business in future.
Further future of connectivity half-days will address the topics of umati
and energy efficiency through digitalization. Sustainability in production
aspects will finally be covered in presentations and discussions on e-mobility,
climate-neutral production, the potential of circular business models and
best practices with regard to sustainability in production.
VDW hall 8, booth B53 / umati hall 9, booth F24
further information: www.emo-hannover.de
High level of innovation with
six-sided complete machining
Anyone using EMO as an opportunity
to discover any kind of innovation for
their company will find satisfaction with
the CHIRON Group.
If one is familiar with the world of six-sided
complete machining with milling and turning,
one knows about the benefits when machining
highly precise, complex and thus often very expensive workpieces. Even the
very first produced part must have the correct dimensions. The MT 715 two+
and the FZ 08 S mill turn precision+ stand up to these demanding requirements
at the fair. The machining centers will show why the six-sided complete
machining system with integrated automation always means a productivity
boost for customers.
Micro5: the number one in micro-machining
In a very short amount of time, the smallest and most energy-efficient machine
from the CHIRON Group has become a bestseller. The USPs of the
Micro5 are sustainable and ultraprecise, with an energy requirement of just
0.5 kW/h, size of under 1 m 2 and micron-level precision. Together with the
automation Feed5, the Micro5 features high autonomy. With a workpiece
blank of 50 x 50 x 3 mm (capacity of over 1,200 blanks) and an assumed cycle
time of 10 min, that equates to eight days of automated production.
hall 12, booth C50
further information: www.chiron-group.com
no. 3, August 2023
47

EMO
Powerful and productive
New 5-axis machining center F 6000 from HELLER
At EMO 2023 HELLER will present the new generation
of its F 6000 machining center for the first time.
The 5-axis machine with head kinematics was designed
from the ground up for flexible series production.
Like all HELLER machines, it sets a benchmark for cutting
performance and precision, including free chip fall, short
idle times, optimum automation capability and compatibility
with the H and FP series for a wide range of workpieces. The
F 6000 also scores with first-class equipment and expandability
with technologies such as mill-turn, interpolation turning
or power skiving. The team led by HELLER’s head of development,
Dr. Manuel Gerst, kept a close eye on these topics, as
well as consistent standardisation and the use of key components
‘Made by HELLER’.
Highlights of the new generation include the completely
redesigned swivel heads and the new integrated motor spindles
specially developed by HELLER. The spindle units deliver
the highest levels of precision, dynamics and cutting performance
for 5-axis machining.
For combined milling and turning operations, the machine
is equipped with the optional Mill-Turn function, in which
the high-torque DDT (Direct Drive Turning) rotary table
plays a key role. In line with the trend towards complete machining
this eliminates the need for reclamping on separate
turning machines. The results are improved workpiece accuracy
and significantly reduced cycle times, especially for series
products. The pallet changer is included as standard as
the first level of automation. The new ‘Automation ready’ option
enables easy integration of the HELLER rotary pallet
storage (RSP) and HELLER’s standardised linear magazine
solutions at a later date.
HELLER will present for the first time the new generation
of its F 6000 machining center
For maximising in day-to-day production, HELLER’s design
engineers have focused on clear and easy operation as
well as good accessibility to all work areas. The new Siemens
SINUMERIK ONE control fitted as standard and the convenient
control unit in panel design with 24” touch screen make
operation easy. At the same time, increased access to the
work area and the optional new SETUP-Assist make it easier
to set up processes on the machine.
At the heart of HELLER’s trade show appearance will be
360° performance – a holistic view of the requirements of
modern production. To achieve this, HELLER focuses on five
solution areas. In addition to the F 6000, HELLER will be
presenting products for the digitisation of production, a comprehensive
range of services as well as innovative manufacturing
processes and technologies for complete machining on
a single machine.
hall 12, booth C68
further information: www.heller.biz
“Diamond purchases are a matter of trust”
At EMO in Hanover LACH DIAMANT can now
look back on 100 years of existence after it was founded
by Jakob Lach in 1922.
At the moment, it is a timeline of international pioneering
anniversaries, for example
→ 1969 the first CBN Borazon® grinding wheel, 55 years ago
→ 1973 introduction of the first polycrystalline
diamond cutting tools – exactly 50 years ago
→ 1975 first CBN cutting tools – 48 years ago
→ 1978 spark erosion was discovered for the production of
polycrystalline diamond tools and registered for patent –
45 years ago
Everything you will see at EMO, proven and new, is built on
the discoveries, developments, and accumulated knowhow of
the company.
LACH DIAMANT is a partner to manufacturers of wind
power systems, the aircraft and automobile industry and its
suppliers, toolmaking (composite, plastic, graphite) and tool
manufacturing industries, electrical and medical industries
and many other industries.To this day it’s focus is still
on “custom made”, and shows the versatility of the company’s
product portfolio, originating from its headquarters in
Hanau.
By the way, last year our subsidiary in Grand Rapids/
Michigan, USA, celebrated its 40 th anniversary as independent
manufacturer of PCD
cutting tools for the
American market, and
continues to strive to
equal LACH DIAMANT
Germany.
hall 4, booth D48
further information: www.lach-diamant.de
48 no.3, August 2023

EMO
The customer-oriented REvolution continues
At EMO in Hanover STUDER will present a new
automation solution at the joint stand of the UNITED
GRINDING Group. Fritz Studer AG, one of the market
and technology leaders in universal, external, internal
cylindrical, and non-circular grinding, will present a
new automation solution on the S31 universal external
cylindrical grinding machine at EMO 2023
Additionally visitors can look to other machines on display:
• favorit – the price hit for the most important applications
• S33 with uniLoad – the value for money
for individual requirements
• S100 – the ergonomic machine for the entry-level segment
• S131R with roboLoad – the expert for every conceivable
internal grinding task
With the first-time presentation of C.O.R.E. at EMO 2021
in Milan, the UNITED GRINDING Group has triggered a
revolution in the field of machine tools. The advanced hardand
software architecture on which C.O.R.E. is based enables
a novel machine interaction concept.
But C.O.R.E. is much more than just a revolutionary operating
system. It opens up new possibilities for networking,
controlling, and monitoring the production process and
thus for process optimization. It also lays the foundation for
the operation of modern IoT applications and thus opens
the door to the digital future.
hall 11, booth E34
further information: www.studer.com
Meeting complex challenges with smart solutions
At EMO Schwäbische Werkzeugmaschinen GmbH
(SW) will present two new products: the two-spindle
BA W03-22 CNC machining center and the BA profile,
a new machine concept for machining profiles.
Furthermore, SW will be showing the BA space3, currently
its largest machine for machining battery housings, and will
be offering insights into current trends in manufacturing
such as friction stir welding and giga casting.
“Innovate Manufacturing” is the theme of this year’s EMO,
which also captures the very essence of SW’s “Smart Manufacturing
Solutions” corporate claim. “For us innovative and
smart manufacturing are two sides of the same coin,” says
André Harter, head of marketing and business development
at SW. “Both allow us to respond individually and efficiently
to our customers’ needs. At EMO Hannover we also want to
reinforce our ‘Be smart. Be part’ theme. This applies not only
to sustainability, which we are driving forward at SW with
our ECO2 machining programme. It also applies to our technology
people. They are at the heart of our vision and our
smart solutions.” The market leader for multi-spindle machines
will be exhibiting three machines from its extensive
range of smart manufacturing solutions, two of them for the
first time.
Efficiency boost for the automotive industry
Productivity, flexibility, modularity, and connectivity: these
are the most important factors for SW when it comes to
meeting challenges with efficient system solutions in the
fast-growing field of e-mobility. Case in point is the new
BA W03-22 CNC machining center. Thanks to its high precision
and efficiency, this two-spindle machine is ideal for producing
high-quality workpieces in medium and large series
for the automotive industry. Compared to a single-spindle
machine, cycle times can be reduced many times over, ensuring
maximum productivity. “We have expanded the
Smart Manufacturing Solutions from SW offer increased
productivity, flexibility, modularity and connectivity
proven machine concept of the model 3 series to include a
two-spindle, double-station machine. It allows for faster axis
accelerations with the linear motors installed in the machine,”
explains Harter. “As a result we achieve more power and
speed compared to a ball screw as in the BA 322 model, for
example with 20 % faster chip-to-chip times.” With 300 mm
of travel, the BA W03-22 also positions in G0 30 % faster than
the BA 322. The machine is the first from SW to be equipped
with Siemens Sinumerik One control.
Flexible machining with BA profile and BA space3
Another highlight is the new BA profile. Featuring a compact
design, the two-spindle machine has two operating areas and
allows machining on two worktables per side. It can be loaded
either via automation or ergonomically by hand.
hall 12, booth C04
further information: www.sw-machines.com
no. 3, August 2023
49

EMO
Smart sensor technology
Integrated solution for the factory of the future
With its intelligent components, the Smart
Automation and Monitoring System (SAMS) by Balluff
provides important information about the condition
and control of machines and entire systems. The portfolio
is extensive, with a focus on the integration of
software and hardware.
Small batch sizes, different types of parts, external influences
and time-consuming error search on production lines: the
challenges for users in manufacturing and logistics companies
are increasing. Possible consequences include long setup
times, downtime and production loss. At the same time the
importance of efficiency and effectiveness in industrial automation
is growing. This is where the Smart Automation and
Monitoring System (SAMS) by sensor and automation specialist
Balluff comes in. With intelligent devices, it provides
important data about the condition of individual machines
and entire systems. Smart functionalities also enable various
automation tasks to be solved directly in the sensor, eliminating
a controller, as data preprocessing already takes place in
the sensor itself.
Capture, analysis and diagnosis
Smart, powerful sensors and network components form the
core of the system. The SAMS portfolio includes various
URMA AG has been a drilling expert in the field of precision
tools for over 60 years. Under the motto “Innovation is our
tool”, the family-owned company with its production site in
Rupperswil (Switzerland) develops and manufactures preciproducts
such as optoelectronic sensors, digital position indicators,
inductive sensors, identification systems and IO-link
masters. These can be individually programmed, configured,
and easily implemented. Once attached to machines and
equipment, the sensors continuously capture important measurement
values such as vibration, temperature or exceptional
environmental conditions. “Possible deviations and trends
are recognized and analyzed in the subsequent comprehensive
data analysis and diagnosis, with logical connections being
directly inferred,” explains Dennis Seng, automation solution
manager at Balluff. “The gathered information from
cross-machine monitoring helps to identify or even prevent
potential malfunctions, enabling timely responses and alleviating
the burden on the control level.”
Focus on smart factory
Combining classic automation technology (OT) and information
technology (IT): the Smart Automation and Monitoring
System (SAMS) stands for the comprehensive automation
philosophy of the company from Neuhausen auf den Fildern –
and paves the way to the intelligent factory in times of the
Industrial Internet of Things (IIoT).
hall 9, booth F23
further information: www.balluff.com
Precise, process-reliable and efficient milling
URMA AG is expanding its precision tool range
with the diamond-tipped MX diamond shoulder
and face shell mill tool, which is suitable for machining
light metals such as aluminum. Here, too, URMA
relies on the patented quick-change system, which
promises the best handling and maximum precision.
MX diamond is available in three different diameters:
63 mm, 100 mm and 125 mm
sion tool systems that are used worldwide in the mechanical
engineering, automotive, hydraulics and aviation industries.
The market for light metal workpieces and their machining
tools is constantly growing. The use of known shoulder
and face mill tools works, but the handling is complex and
time-consuming. The company has applied its vast experience
in the application of high-precision quick-change cut-off
points. The result: MX diamond is a completely new shoulder
and face shell mill system. With this modular cutting tool,
URMA relies on the proven and highly precise RX quickchange
cut-off point, which guarantees perfect axial run-out
without needing subsequent correction when changing cutting
edges. The teeth of the solid carbide cutting edge body
are fitted with up to 20 PCD (polycrystalline diamond) tips
and are ideally suited for machining lightweight materials
such as aluminum, magnesium, copper-containing metals
without iron, composites and fiber-reinforced plastics. This
latest generation of face milling ensures lean production processes
and automated production. Thanks to the high tool rigidity
of the MX diamond, both finishing and roughing cuts
can be made with the same cutting edge. With a feed rate of
0.05 - 0.3 mm per tooth and a cutting speed of up to 5000 m/
min, MX diamond is ideal for series production. Various geometries
are available to meet individual requirements.
hall 5. booth A63
further information: www.urma.ch
50 no. 3, August 2023

EMO
Machining center with tilting table
for enhancing precision manufacturing
The FEELER VUX 400 4/5-axis machining center designed to
meet the diverse machining demands and applica tions. With its
multi-axis capability, it surpasses three-axis machines and enables
machining of special angles and complex multi-curved workpieces.
The machine is suited for various industries, including:
→ automotive industry: machining automotive parts, eg. cylinder heads
→ medical industry, eg. orthopedic devices
→ mold and die industry: machining precision molds and dies
→ energy industry: machining components for power generation equipment
• X/Y/Z axes travel: 650/520/480 mm
• A(B)/C axes rotation angel: +30 ~ -120 °/360 °
• table size:
0350 mm
• spindle speed:
DDT 12000 rpm
• X/Y/Z axes rapid traverse: 30/36/30 mm
• number of tools: 24 T
The machine’s boasts a range of key features that enhance its performance
and versatility. It offers one-time workpiece clamping and positioning, enabling
streamlined machining processes with reduced processing time and
repetitive positioning. Additionally it excels in machining undercut areas,
eliminating the need for additional forming tools and expanding its capabilities
for complex surface machining applications.
Capable to process deep hole molds, the machine not only reduces tool
wear but also doesn’t need any special fixtures, resulting in cost optimization.
The FEELER VUX 400 incorporates improved cutting tool rigidity by
reducing tool length, leading to enhanced cutting performance, extended
tool life, and superior surface roughness. These combined features make the
VUX 400 an exceptional choice for precision manufacturing needs.
hall 12, booth B68
further information: www.ffg-ea.com
EDM wire machines from € 3 / hour operating costs
Ageltech GmbH is a manufacturer
and supplier of electro-erosion machines
and CNC diamond wire saws with an
outstanding price-performance ratio.
The EDM machine supplier also has a M-series
in its range, spark erosion wire machines
based on molybdenum wire technology. The
simple and clearly designed machines feature
outstanding operating costs from less than
€ 3 / hour incl. depreciation and amortization
over 5 years with € 25 k acquisitions costs. Molybdenum wire technology is
little known in Europe, but all the more so in Asia. Well over half of the wire
erosion machines there work with molybdenum wire technology. In general
this technology is suitable for cutting conductive materials, e.g. from the
usual large vehicle parts (also made of aluminum) to tools made of steel (including
carbide steel) to small medical products made of special alloys.
Ageltech offers very affordable entry-level machines with manual wire
threading. It is most advantageous for works with either long, continuous
eroding or where the eroding path can be eroded briefly into the workpiece
from the outside, i.e. without a starting hole. Cutting contour accuracies up
to +/- 10 µm and roughness up to Ra 0.8 µm display the impressive quality
possibilities.
The molybdenum wire technology achieves cost advantages mainly
through the multiple reuses of the wire. It is rolled up and down during the
process. This can be done for several working shifts with the same wire, with
one winding usually being just under 200 m.
Another source of the cost advantage is the simple rinsing of the wire with
a water-based antioxidant agent instead of the usual technology in an immersion
bath. The workpiece remains in the air and only the sparking area
being machined is flushed. The whole handling is easy and machines are
available from R&D applications to industrial mass production.
The M-series is available in many sizes from working areas of
320 x 450 x 200(h) mm³ up to 1,300 x 1,900 x 500(h) mm³. Special sizes on
request.
hall 6, booth C51
EDM wire machine M200
further information: www.ageltech.de
no. 3, August 2023
51

EMO
Ready to lead the future of machining solutions
The machine tool manufacturer
SORALUCE will demonstrate at EMO
2023 its international leadership in
milling, boring, multitasking and automated
solutions, presenting the New
Performance Line, the New Generation
of Heads, and also the most competitive
technologies and services.
SORALUCE has taken another step forward
to extend its range of milling, boring, multitasking
and automated solutions. The machine tool manufacturer has now
added a new line of milling machines to its product portfolio to help furnish
a response to challenges in the sector, offering added-value solutions in the
most demanding industrial environments.
The new Performance Line provides the highest reliability and precision
along with an outstanding flexibility for medium/large workpieces.
A common structure, three different types of architecture and countless
solutions to adapt to the needs of each of the customers in the most competitive
manner possible.
Each of these families caters for several models and setups (fixed table,
rotary table, multitasking), producing machines that can be configured
for different work environments. These are three ranges sharing the main
machine features, such as the column, saddle, ram and heads, built on the
principle of modular design, to give high reliability, easier service and flexibility
to devise a solution for the customer.
Performance Line has the same design principles as SORALUCE’s heavyduty
machine range: Soraluce Winning Combination, providing the most
rigid and dynamic solution available on the market, with a combination of
a cast iron structure, linear guides and active/passive damping technology.
It applies all the experience the manufacturer has gleaned from its larger
models, and has chosen the solution to offer more precision and reliability:
direct drive inline motor with high power and torque in the ram, equipped
with a 32 kW motor capable of reaching rpms up to 8000. The motor is
water-cooled to boost thermal stability and secure the best precision machining
results.
hall 13 booth B30
further information: www.bimatec-soraluce.de
Metallurgical solutions combining performance,
longevity and reliability
Erasteel, world leader in Powder
Metallurgy High-Speed Steels for over
50 years which provides solutions combining
performance, longevity and reliability,
is about to launch a new product
BlueTap®Max dedicated to high-performance
taps
Thanks to a long-standing know-how, a longterm
partnership with customers and a highly
qualified R&D team, Erasteel offers ever more
innovative, high-performance, and sustainable
Powder Metallurgy (PM) High-Speed
Steels (HSS) grades.
Only player in the world dedicated to High-
Speed Steels and major player in strategic
metals recycling, Erasteel is:
→ world leader in Powder Metallurgy High-
Speed Steels for over 50 years: the premium
ASP®, PEARL® and BlueTap® ranges
provide its customers a long-term solution with longer lifetime, better
performance and lower maintenance.
→ major international player in sustainable Powder Metallurgy and
conventional High-Speed Steels: Erasteel offers high-performance
products made from over 92 % recycled materials and aims to become
very soon the first producer to reach 100 % recycled HSS
→ European leader in the recycling of batteries and oil catalysts by
pyrometallurgy: thanks to a unique process in the world, Erasteel
provides a second life to strategic metals with high added value
contributing to preserve natural resources.
Innovation is in the company’s DNA: Erasteel provides global industry with
metallurgical solutions that comply with the new challenges of market demand
evolution.
In September at EMO the company will announce the launch of a new
grade for high-performance taps named BlueTap®Max. BlueTap®Max increases
significantly hardness and grindability thanks to a unique concept of
powder-metallurgy alloys. These unprecedented technical properties deliver
unrivalled performances with optimized total cost of ownership.
hall 4, booth G33
further information: www.erasteel.com
52 no. 3, August 2023

EMO
Highest precision with extra technology
At EMO 2023 Kern introduces for the
first time the advanced five-axis machining
center Kern Micro HD with a new
Fischer CSC spindle and high-end control
Heidenhain TNC 7. Furthermore
visitors can engage with Kern Micro
HD and with the laser machining center
Kern Femto E3.
Visitors will see three precision machines.
Among the precision machines, they can also
find many individual innovations, with which
the Kern Micro HD can be equipped in the
future. Just one example: the highly effective
shaft cooling of the new CSC HSK 40 spindle
reduces the previously required warm-up
time to almost zero.
The company’s experts and advisors will be explaining the resulting opportunities
for applications as well as the technical background of all displayed
parts. Visitors can look forward to experiencing the Kern Micro HD,
which was launched in 2020 and is now very popular with more than 150 installed
machines worldwide. Eight different sample parts in different materials
will be machined. Extremely hard and softer metals as well as ceramics
and graphite. The machining center proves its versatility and reliability when
it comes to precision and surface quality in the µm area.
As a third machine Kern Microtechnik will present the laser machining
center Kern Femto E3. It will machines in regular intervals heading tools for
cutting inserts. The advantage of laser machining is the lack of tool costs and
the stability of the process, while achieving accuracies of +/-3 µm and surface
qualities of Ra = 0,1 µm. Other applications for this technology are for example
surface texturing and applications in mold & die.
hall 12, booth D60
further information: www.kern-microtechnik.com
Small differences that make a big impact
Oerlikon Balzers, a leading global
technology brand of the Oerlikon Group,
will showcase its latest high-tech surface
solutions at EMO. The S3p coating
BALIQ TISINOS PRO for hard machining
up to 70 HRC will be shown for the
first time, while other highlights include
the carbon coating BALINIT MAYURA,
the diamond coatings from the BALDIA
family and advanced digital production
and connectivity technologies.
Products and services from the sister brands
Oerlikon Metco and Oerlikon AM complete
the trade fair line-up, where the theme is
“Small difference, big impact”.
In a milling test, the innovative
BALIQ TISINOS PRO coating achieved up to
50 % longer service life than its predecessor
Improved performance in machining hardened and stainless
steels and high-temperature alloys
BALIQ TISINOS PRO, the latest coating innovation from Oerlikon Balzers,
clearly demonstrates how small differences can have a big impact. BALIQ
coatings are based on the S3p (Scalable Pulsed Power Plasma) coating technology,
which combines the advantages of arc evaporation and magnetron
sputtering processes to push the boundaries of conventional HiPIMS coating
performance. The microstructure and smoothness of BALIQ TISINOS PRO
have been further enhanced, resulting in even better wear resistance. When
machining high-temperature alloys and stainless and hardened steels up to a
hardness of 70 HRC, the AlTiSiN coating withstands high thermal loads and
ensures an even more stable process. Tests with end mills have shown an average
increase in tool service life of up to 50 % compared to its predecessor
coating with higher production quality, particularly in micro-machining.
Carbon and diamond coatings for non-ferrous metals,
lightweight construction and more
Introduced in 2022, BALINIT MAYURA is attracting increasing attention,
and not just because of its rainbow color. The thin and extremely hard
ta-C coating for machining non-ferrous materials such as aluminum, copper,
brass alloys and polymers minimizes material build-up on the tool while
maintaining extremely sharp cutting edges. High precision, longer tool service
life and increased productivity are the reasons why toolmakers and end
users are increasingly turning to BALINIT MAYURA.
The BALDIA family from the company serves innovative markets such as
the dental, automotive, and aerospace sectors but also traditional industries
like mold making. These CVD diamond coatings are ideal for the highly
abrasive machining of graphite, ceramics or CFRP/GFRP materials, supporting
sustainable manufacturing solutions in electromobility and lightweight
construction. For example, BALDIA COMPOSITE DC has tripled the tool
service life of CFRP drills in aircraft construction while reducing tool costs
by more than half.
hall 4, booth B18
further information: www.oerlikon.com
no. 3, August 2023
53

EMO
Effortless start into automated quoting
Spanflug Technologies will present its
quoting solution in its latest version at
EMO. The cloud-based software aims to
streamline the otherwise complex and
tedious process of preparing quotes for
custom turning and milling parts and reduces
efforts by up to 90 %.
It addresses the challenges faced by machine
shops, such as excessive time and cost spent
on administrative tasks, increasing competitive
pressures and uncertainty resulting from
the growing complexity in stocks procurement.
With its industry-leading, innovative
algorithm, Spanflug Make sets new standards
in automated quoting.
Seamless digital solution from CAD
model to ready-to-send customer
quote
With Spanflug Make machine shops calculate
prices for turning and milling parts in one
minute. The software supports throughout the
entire quoting process – from receiving RFQs
to sending out final quotes to customers.
Main features of Spanflug Make include:
→ the software technology automatically extracts
all data for manufacturing from CAD
models and technical drawings, which users
can securely upload; the smart parts analysis
eliminates manual data entry and enables
also unskilled employees to prepare precise
customer quotes easily and autonomously
umati is back
At EMO Hannover 2023 it can be
stated: umati is back! And bigger and
more comprehensive than ever before. In
Hannover, the community of now more
than 300 umati partners will demonstrate
live how easily decentralized communication
between machines, components
and software works – and well beyond
the machine tool.
umati (universal machine technology interface)
is the global initiative for open communication
interfaces for the machine building
industries and their customers. Machine
builders, software manufacturers, component
suppliers and users have uniting forming
a strong community to promote the use of
open, standardized interfaces based on OPC
UA companion specifications. umati ensures
their identical implementation, provides a
platform for exchanging experiences, creates
→ prices and manufacturing times are automatically calculated by the
intelligent algorithm, which has been tested and is subject to continuous
AI-based and data driven improvements; it also includes up-to-date prices
for nearly 60 materials and over 30 post-treatments, reducing uncertainty
in supply chains and achieving the calculated margins despite price
fluctuations; details like machining times, stocks or tools needed, are
also provided and support machine shops in manufacturing planning
→ immediate use or customized for the individual machine shop in just
a few simple steps by setting up CNC machines and adjusting settings
such as cutting values or markups
→ Spanflug Make increases the efficiency of the entire quoting process; suiting
a wide range of operational settings – from companies with established
IT systems to smaller machine shops at the beginning of their digitization
journey; with possibilities to manage customer master data directly within
Spanflug and to either export calculation results to existing ERP systems
or to conveniently generate a quote.
→ Spanflug Make is a software-as-a-service solution that can be used
without installation and maintenance efforts, calculating five parts per
month is permanently free, while monthly or annual software
subscriptions are available for unlimited calculations
hall 9, booth H22
further information: www.spanflug.de
visibility in the market and demonstrates the added value in a practical way.
Meanwhile more than 300 umati partners participate in the umati community.
More than 50 % are companies or institutions abroad, and 80 % are corporate
partners. This makes umati truly a global initiative by companies for
companies, and the only initiative that provides a live demonstration of the
concrete exchange of data in a shared, globally available data ecosystem.
The central point of contact at EMO will be the umati booth in hall 9, F24.
Meet-the-experts sessions will be held several times a day. Interested parties
can obtain first-hand information from the umati team and representatives of
umati partner companies about the background, technology and benefits of
open, standardized data interfaces for mechanical engineering. With the help
of various exhibits it will be demonstrated how mature the technical solutions
have become. In the immediate vicinity are the booths of the OPC
Foundation and the Machine Information Interoperability (MII) department
of the VDMA. This represents the strong triad of OPC UA as a base technology,
the Gobal Production Language driven by VDMA in the form of OPC
UA companion specifications for the numerous technologies of machine and
plant engineering, and umati for implementation and marketing.
hall 9, booth F24
further information: www.vdw.de
54 no. 3, August 2023

An impressive lineup of machines and solutions
EMO
DN Solutions unveils 19 advanced
ma chine tools at EMO Hannover, an impressive
lineup of machines and solutions
across three sections: Flexible Automation,
Real Digitalization, and Green
Forward.
In the Flexible Automation section, DN
Solutions will demonstrate more advanced
automation solutions in collaboration with
various companies specialized in automation,
including robot automation. Visitors will witness
the seamless integration of various work
handling solutions, such as robots, gantry systems
and pallet handling solutions, into its
advanced machine tools. The section will exhibit
automation solutions that utilized the
compact turning center LYNX 2100LSYB and
the collaborative robot COBOT, and automation
solutions that apply the gantry loader to
the high-productivity two-spindle horizontal
turning center PUMA TW2600M. DN Solutions
will boast of its technological prowess,
with expanded automation area, such as applying
the rotary pallet system to the highproductivity
horizontal machining center
NHP 5000 and applying AWC to
the compact 5-axis vertical machining
center DVF 4000.
In the Real Digitalization section,
DN Solutions will introduce
smart manufacturing solutions
based on user-friendly digital
transformation technology. DN
Solution will actively emphasize
the benefits of digital twin technology,
such as minimizing risks through virtual verification and reducing
machine setup time. With multi-tasking machining turning center
SMX3100ST, DN Solutions will also exhibit the skiving machining technology
using the table turning function. Additionally, live machining demonstrations
will be conducted, carefully selecting machining items to effectively
showcase the unique features and characteristics of each machine.
The Green Forward section will exhibit the energy-saving solutions of DN
Solutions, which lead environmental protection, such as the mist-free solution
for oil mist purification, the power consumption monitoring system.
Specifically the mist-free solution offers the advantage of minimizing motor
power, resulting in reduced power and maintenance costs. In pursuit of this
goal the solution is designed to be compact, transitioning from a factory unit
to a machine tool unit.
hall 14 booth D06
further information: www.dn-solutions.com
Manufacture more parts faster
The skilled labor shortage, disruptions
in supply chains and rising costs for mate -
rials and energy are affecting manufacturing
companies involved in machining.
That is why industry is searching for ways
to improve efficiency and flexibility in
order to manufacture more parts faster,
resulting in that more machines need to
be operated by fewer employees.
This solution is reinforced by increasing automation
with pallet changers or handling
A CAD/CAM process helps to program complex
machine tools with multiple spindles, tool
carriers or units: here, parting off the workpiece
and transferring it to the second spindle
systems. Machining centers need to be operated unattended, so that employees
can manage these tasks. The machine needs an NC program that covers
all operations, from the setup of a blank and provision of the required tools
to removal of the part. This NC program has to be complete and error-free.
Achieving this goal requires digitalization and automation before the machine:
i.e., before machining. If all the tasks are prepared in advance in the
virtual world using precise digital twins, there won’t be any surprises during
machining. For example, if the programmer has a precise digital model
of the planned setup situation and the machine and works with digital
twins of the machining tools, including precise geometric data and cutting
data tested in practice, the result is an NC program that already fulfills most
of the above requirements. A subsequent complete simulation in the CAD/
CAM environment provides the final safety element for all traverse movements
and limit switches. This is also ensured by output via a postprocessor
that’s been certified by the CAD/CAM provider. This delivers complete NC
programs with sequences for turning, milling, drilling and even measurement
integrated in the process.
Fast NC programming with automated rules in a knowledge base
Modern automated machining centers have a high part throughput and
therefore require a large volume of NC programs. This means that the NC
programming process needs to be automated, by compiling the company’s
manufacturing knowledge, saving it and making it available in automated
rules in a knowledge base.
hall 9 booth A28
further information: www.tebis.com
no. 3, August 2023
55

EMO
Adjustable damped boring bar
Long tool overhangs can cause a turning tool to oscillate
when boring internal geometries. In addition
to the resulting chatter marks on the surface, these vibrations
also lead to a significant reduction in tool life.
For unfavourable length/diameter ratios, the experienced
machinist relies on vibration-damping boring
bars, which enable low-vibration machining but which
can still vibrate during certain machining operations.
Paul Horn GmbH has addressed this problem and is presenting
a boring bar at EMO in Hannover that can be adjusted to
the vibration amplitudes that occur. Precise adjustment of the
damping element in the boring bar enables a vibration-free
grooving process. This results in better surface quality without
chatter marks and a significant increase in tool life.
The exact adjustment of the damper, made of a carbide rod
supported in O-rings, is made from the outside via an adjustment
screw. Adjustment is achieved by fine-tuning the pretension
of the O-rings. This allows the boring bar to be precisely
set according to the vibration occurring in each application.
As standard Horn offers the tools from stock in
the length/diameter ratios 5 x 0 and 8 x 0. Higher ratios are
possible as special tools. For the grooving processes, Horn offers
the S224 double-edged grooving system. The Horn cassette
system BK 224 ensures a stable interface between the
boring bar and the inserts. To further increase process reliability,
the boring bars are equipped with an internal coolant
supply.
hall 5, booth A54
further information: www.horn-group.com
Customer care special exhibition area and
machine highlights
The UNITED GRINDING Group, one of the
world’s leading manufacturers of grinding, eroding,
laser, and measuring machines as well as machine
tools for additive manufacturing, is considered one of
the pioneers in the development of innovative technologies
in its industry. “Innovate Manufacturing” is
the motto of this year’s EMO Hannover, therefore, the
group cannot be absent.
With its special exhibition area, the group is placing a focus
on Customer Care this year. This includes all products and
services that accompany customers during the service life of
their machines and support them in efficient production –
from “start up” to “retrofit”. Nevertheless, visitors to the trade
show can also obtain comprehensive information about all of
the group’s digital assistance systems. These include the Production
Monitor, the Service Monitor and the Remote Service,
which are grouped under the name UNITED GRINDING
Digital Solutions. In addition, further digital solutions will
be presented at EMO.
Moreover, the public can look forward to several innovations
and highlights among the 16 machines on display:
BLOHM, the specialist for surface and profile grinding machines,
is celebrating a world premiere: the PLANOMAT XT
408 with automatic workpiece loading and unloading as new
solution for internal machining of hydraulic motor stators.
STUDER will also present a novelty: an innovative automation
solution that will be on display on the S31 universal
external cylindrical grinding machine.
And WALTER is presenting for the first time the innovative
“Laser Contour Check” measuring system at EMO, for
highly accurate, non-contact measurement of various tool parameters
on cylindrical tools, which is now also available as
an option for the HELITRONIC MICRO and HELITRONIC
MINI PLUS tool grinding machines.
hall 11, booth E34
further information: www.grinding.ch
56 no. 3, August 2023

EMO
Mechatronic solutions for metal working
When it comes to international competition,
there ary many challenges for
European manufacturing companies
nowadays. However with the careful use
of digitisation, including artificial intelligence
in combination with robotics and
other automation solutions, it’s possible
to make significant leaps in productivity to guarantee increasingly
stable competitiveness.
This is where the mechatronic solutions developed by HSD come into play.
In fact, EMO will be an unmissable opportunity to get an exclusive preview
of the new ES1020 and ES1040 electrospindle models, developed by HSD to
complement the ES10 Line. The result of technological advancement and
continuous collaboration between our engineering team and our customers,
based on their requirements, these new electrospindle models are able to
adapt to the multiple needs of users and the ever’-increasing pace sought by
today’s market.
In line with the future trends of digitisation and Industry 4.0, HSD will
present a preview of a special “connecting device” which, from now on, can be
installed on the range of electrospindles dedicated to metalworking, allowing
them to be connected to the myHSD IoT platform via a series of sensors.
The connecting device developed by HSD therefore follows the leit motiv
of the event, helping to “innovate manufacturing” and making production
processes more efficient and effective, increasing productivity and quality
while minimising errors and machine downtime.
hall 12, booth A16
further information: www.hsd.it
New standards in the machining of
profile plates and shank tools
Schütte’s 105linear five-axis grinding
machine reduces the setup effort for machining
profile plates and shank tools to
a minimum.
When it comes to grinding cutting tools such
as drills, milling cutters and profile plates,
the proportion of small batch sizes through
to single-part production is increasing. At the
same time demands on shape and dimensional
accuracy and resulting surface qualities
are increasing. In this context, contour tolerances
in the lower micrometer range must be
maintained during grinding, which means
that ideally the first part is also directly a good
part. The bigger the batch size, the more likely
it is that a set-up effort will be tolerated due to an iterative correction of the
grinding result. Especially in the case of single-part production, however,
this setup effort must be reduced to a minimum. The Schütte 105linear offers
the highest first part accuracy, but is also optimally suited for series products
due to its high process reliability.
Highest accuracy with only one measuring process
Also the application area of profile plates deserves special attention. Unlike
cylindrical cutting tools (especially drills/mills/cutting punches), the clamping
of these workpieces is already highly interesting. The nail clamping technique
is a proven, reliable and productive solution for positioning profile inserts
for grinding in the machine and also for machining multi-bladed inserts
over the entire circumference. It is also here important to achieve the
highest accuracies, so the subsequent contact surfaces of the indexable insert
in the toolholder can be measured individually and the grinding contour automatically
adapted to it. This guarantees that in the final use of the workpiece,
no further measurement is required when indexing the insert again –
even for the highest quality demands. The 105linear series is also suited for
this workpiece category because high grinding feeds can be carried out with
the highest precision, which offers an immense productivity advantage.
Simple and fast measurement through automation
Already during process preparation, the machine as well as the robot and the
grinding wheel handling are automatically measured. That’s easier and faster
than manual measurement, and the machine operator can then devote himself
to more important tasks.
hall 6, booth G13
further information: www.schuette.de
no.3, August 2023
57

fairs in alphabetical order
AMB Stuttgart, Germany
(September 10-14, 2024)
bauma Shanghai, China
(November 26-29, 2024)
CMTS Toronto, Canada
(September 25-28, 2023)
DEBURRING Karlsruhe, Germany
EXPO (October 10-12, 2023)
EMO Hanover, Germany
(September 18-23, 2023)
FABTECH Toronto, Canada
(June 11-13, 2024)
FEIMEC São Paulo, Brazil
(May 7-11, 2024)
GrindingHub Stuttgart, Germany
(May 14-17, 2024)
GrindTec Leipzig, Germany
(March 11-14, 2025)
Hannover fair Hanover, Germany
(April 22-26, 2024)
IMTS Chicago, USA
(September 9-14, 2024)
JIMTOF Tokyo, Japan
(November 5-10, 2024)
METALEX Bangkok, Thailand
(November 22-25, 2023)
MSV Brno, Czech Republic
(October 10-13, 2023)
SIAMS Moutier, Switzerland
(April 16-19, 2024)
SIMTOS Seoul, South Korea
(April 1-5, 2024)
sps Nuremberg, Germany
(November 14-16, 2023)
SteelFab Sharjah, United Arab
2024 (January 8-11, 2024) Emirates
Stone+tec Nuremberg, Germany
(June 19-22, 2024)
Surface Stuttgart, Germany
Technology (June 4-6, 2024)
TMTS Taichung, Taiwan
(March 27-31, 2024)
current status
2024
2024
2023
2023
2023
2024
2024
2024
2025
2024
2024
2024
2023
2023
2024
2024
2023
2024
2024
2024
2024
trade fair dates as by middle of August 2023; we are not responsible for reliability of these dates
58 no.3, August 2023

impressum
ISSN 2628-5444
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AGELTECH GmbH ..................51
Alfred H. Schütte GmbH & CO. KG ....57
ARCH Cutting Tools ................ 20
Balluff GmbH. ......................50
BIMATEC SORALUCE
Zerspanungstechnologie GmbH. .....52
Boehlerit GmbH & Co. KG ........... 20
Carl Zeiss AG ...................... 46
CERATIZIT
Deutschland GmbH ................21
CHIRON Group SE ..................47
DN Solutions Europe GmbH ..........55
EMAG GmbH & Co. KG ..............18
EMO ...............................47
ERASTEEL .........................52
fairXperts GmbH & Co. KG ...........22
FFG European &
American Holdings GmbH ..........51
Fraunhofer Institute for Manufacturing
Engineerig and Automation IPA .....32
Fritz Studer AG .................... 49
Gebrüder Heller
Maschinenfabrik GmbH ......16, 17, 48
GF Machining Solutions ............ 46
Hartmetall-Werkzeugfabrik
Paul Horn GmbH ............... 6, 56
advertising index
company finder
HSD SpA . ..........................57
KAPP GmbH & Co. KG. . .............36
Kern Microtechnik GmbH ........ 40, 53
Lach Diamant Jakob Lach
GmbH & Co. KG ............... 24, 48
LMT Tools GmbH & Co. KG ..........12
MAPAL Fabrik für Präzisionswerkzeuge
Dr. Kress KG ...................13, 18
OERLIKON BALZERS ...............53
OKUMA Deutschland GmbH .........39
Platinum Tooling Technologies, Inc ....19
Rodriguez GmbH .................. 44
Schunk GmbH & Co. KG .............43
Schwäbische
Werkzeugmaschinen GmbH .........49
Spanflug Technologies GmbH. ....... 54
T e b i s
Technische Informationssysteme AG .55
Tyrolit - Schleifmittelwerke Swarovski
AG & Co. K.G. ......................9
UNITED GRINDING Group .........56
URMA AG .........................50
VDW – Verein Deutscher
Werkzeugmaschinenfabriken .... 23, 54
ZECHA Hartmetall-Werkzeugfabrikation
GmbH ............................10
XEBEC TECHNOLOGY CO.,LTD. ....29
Boehlerit GmbH & Co. KG ...............................................page 13
CERATIZIT Deutschland GmbH .........................................page 5
fairXperts GmbH & Co. KG ..............................................page 39
Fritz Studer AG ............................................... inside front cover
Gebrüder Heller Maschinenfabrik GmbH ..................................page 23
Hartmetall-Werkzeugfabrik Paul Horn GmbH ..........................front cover
Kapp GmbH & Co. KG ..................................................page 15
KELCH GmbH .........................................................page 17
Lach Diamant Jakob Lach GmbH & Co. KG .............................
back cover
Liebherr-Verzahntechnik GmbH AG ......................................page 21
rose plastic AG .........................................................page 19
Supfina Grieshaber GmbH & Co. KG ......................................page 3
VDW .................................................................page 45
WEIMA Maschinenbau GmbH ...........................................page 11
ZECHA Hartmetall-Werkzeugfabrikation GmbH ..........................page 9
no. 3, August 2023
59

Stop long chips
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Find your solution for high surface quality
Visit us at EMO in Hanover in hall 4 / D48!
www.lach-diamant.de · office@lach-diamant.de
®
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since 1922