hpt 2023 #4

ISSN 2628-5444
high precision tooling
Machine Tools, PCD, PVD, CVD, CBN, Hard Metal 2023 – 4
»CONTOUR PROFILED«
shows the claws
Deep grinding with »contour profiled« grinding wheels
Diamond and CBN tools since 1922
® ®
®
®
Titelbild hp tooling leo part e fini.indd 1 04.10.23 14:15
■ First PCF standard for cemented carbide ■ AI is not an add-on job ■ Giga castings in CNC machining ■
■ High-performance grade for thread whirling ■ Automation and digitalization in machine tool building ■

cover story
Technical Support.
When You Need it Most.
As engineers, we know our craft and have a thorough understanding
of production processes. If you need us, we are on hand to help with
extensive expertise.
just-our-thing.uk
THE Cutting Tool Solution
CERATIZIT is a high-technology engineering
group specialised in cutting tools and hard
material solutions.
Tooling a Sustainable Future
www.ceratizit.com
U2 no. 4, November 2023

editorial
Eric Schäfer
editor-in-chief
What is the difference between the pessimist
and the optimist?
None. The pessimist is just better informed, is a joking answer. But this year’s EMO, the world’s leading
trade fair for production technology, proved that a lot of information can also lead to optimism.
Anyone with open ears and eyes could sense a lot of optimism. Understandably so, because the industry
showed its claws at the fair and everything that “constitutes the future of production”, according to
EMO commissioner general Carl Martin Welcker in his summary of the fair. New solutions for
automation, for networking in the factory and for sustainability in production. “When digitalization
meets the factory, the way is clear for new solutions and levels of efficiency. The exhibitors presented
this impressively,” Welcker summed up.
Optimism for the future of the industry could clearly be heard between the lines in the conversations
with the exhibitors, albeit sometimes cautiously expressed. An impression that countered the currently
widespread economic pessimism.
The exhibitors were able to meet the international public’s targeted search for innovations in many
ways. Some of them you can find in this issue of hp tooling. These include numerous new machine tools,
tools and clamping technology that make process solutions simpler, more efficient and more sustainable.
We show you how to better orchestrate large automotive structural components on CNC machines.
We were there when the first Product Carbon Footprint for cemented carbide was presented. This
CO 2 balance provides detailed information on the footprint of indirect emissions caused by tools.
An approach that allows us to look towards the future with optimism.
Eric Schäfer
editor-in-chief
no. 4, November 2023
3

table of contents
cover story
Tradition. Passion. Innovation: LACH DIAMANT – 100 Years – 7 th part
A spark which ignited a technical revolution – and made Horst Lach the inventor of
spark erosion for the machining of polycrystalline cutting materials 6
materials & tools
CNC diamond wire saws to cut 2D contours in glass 12
The first PCF standard for cemented carbide 14
Update on live tooling 16
New high-performance grade for thread whirling 18
Newly developed diamond and CBN grinding wheels for previously impossible grinding tasks 19
Solutions for Advanced Materials 20
processes
Radically faster tool manufacturing 26
Giga castings in CNC machining 28
Functionally integrated implants through novel synchronized machining processes 30
machining center
HELLER 360 ° solutions at EMO 2023 32
Flexible machine concept successfully improved 34
New universal loading system 35
Connecting the art of engineering with digital know-how 36
Perform a variety of grinding tasks in quick succession 38
ULTRA technology enables high quality production of small and micro tools 40
Surface quality and removal rate doubled 41
components
Aerotech brings movement to the automation process 44
New standard clamping devices 47
Door opener to hydraulic expansion technology 48
Tool management made easy 49
news & facts 22
fairs 5
impressum & company finder 51
4 no. 4, November 2023

fairs in alphabetical order
AMB Stuttgart, Germany
(September 10-14, 2024)
bauma Shanghai, China
(November 26-29, 2024)
FABTECH Toronto, Canada
(June 11-13, 2024)
FEIMEC São Paulo, Brazil
(May 7-11, 2024)
current status
2024
2024
2024
2024
FILTECH Cologne, Germany
(November 12-14, 2024)
GrindingHub Stuttgart, Germany
(May 14-17, 2024)
GrindTec Leipzig, Germany
(March 11-14, 2025)
Hannover fair Hanover, Germany
(April 22-26, 2024)
hi Tech & Industry Herning,
Denmark
Scandinavia (Sept. 30-Octob. 2, 2025)
IMTS Chicago, USA
(September 9-14, 2024)
JIMTOF Tokyo, Japan
(November 5-10, 2024)
METALEX Bangkok, Thailand
(November 22-25, 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)
2024
2024
2025
2024
2025
2024
2024
2023
2024
2024
2023
2024
2024
2024
2024
trade fair dates as by middle of October 2023; we are not responsible for reliability of these dates
no. 4, November 2023
5

cover story
LACH DIAMANT – 100 Years
Tradition. Passion. Innovation
part 7:
A spark which ignited a technical revolution –and
made Horst Lach the inventor of spark erosion for
the machining of polycrystalline cutting materials
“When I held my first diamond in my hand in 1908, I would not
have imagined that one day diamonds would not only be used in the
automobile industry but also for the machining of wood and plastics”.
Jakob Lach, the company founder, said this on camera in 1980.
It would become the preface for the first presentation of a new technique
for machining wood and plastics – using diamonds as cutting
material – the Dia Tool. This video, with audio translated into
multiple languages, has lost none of its relevance for the choice of
appropriate tools within the furniture, flooring and composite industries;
the video can be viewed at: https://bit.ly/LACHDIAMANT
Company founder Jakob Lach, 1894-1984
(photo taken in 1980)
Continuing with the 100-year history of LACH DIAMANT®, today I will
take you to the year of 1977. Just for orientation:
46 years ago, Steve Jobs and Stephan Wozniak launched Apple II, the first
PC on the market; William Gates and Paul Allen founded the company
Microsoft, and Voyager 1 and 2 started their journey to Jupiter.
What was happening at LACH DIAMANT?
The pioneer and development activities regarding
polycrystalline (PCD) cutting tools
(since 1973), and now PCBn for turning of
weld-on alloys (as in part 6 “The dawn of CBN
hard turning – turning instead of grinding”)
now show their own success dynamics.
Users and trade press alike were full of
praise. And as if this was not enough, the success
reports we received every day also stimulated
the success of other products from
LACH DIAMANT®. For example, diamond
First time 1977: tool for the cutting of circuit boards
6 no.4, November 2023

cover story
First introduced in 1971:
LACH diamond and CBN tressex® grinding wheels for
deep grinding of HSS with polyamide bond
Hanover fair in 1974: demonstration of the first polycrystalline
diamond end milling cutter dreborid® for cutting fiberglass
materials, first introduced at the Hanover Spring fair
and CBN Borazon® grinding wheels, such as the newly developed
polyamide bond tressex® for deep grinding of carbide
and HSS (slogan: “tressex® shows its claws”) or the “two-inone”
for rough and finish grinding with only one diamond
grinding wheel.
For the dressing of conventional grinding wheels, so-called
drebodress® dressers were developed, based on synthetic
diamonds. In the meantime polycrystalline dreborid®
diamond inserts also passed their baptism of fire with flying
colours during the milling of fiberglass and carbon fiber materials
as well as graphite.
In 1977 a separate product catalogue for “Milling – Cutting
– Drilling and Edge Processing” of composite materials
was created, featuring the now so-called dreborid® K-PCD
tools. The front page was green. Green like most “GRP” fiberglass
materials.
“Was there something else… ?”
…I thought at that time, and I remembered the invitation
to a tradeshow named “productronica” which was scheduled
to take place in Munich, November 1977, for the second
time. Below, I am quoting from my article series “Poly, poly
or what?” (article number 4 in 2020 How a trade show initiated
a brilliant idea…). This announcement of a tradeshow,
unknown to me until then, did, in retrospect, prove to be a
turning point for the recognition of polycrystalline diamond
tools. productronica in Munich 1977 was advertized as a component
fair for the electronic and circuit board industry.
I was interested. Circuit boards? The base material is fiberglass
reinforced plastic (GRP), which was familiar to us. We
successfully cut this with PCD, and dust-free at that.
In order to show this at a fair successfully, we needed a
demonstration machine. We found it at the former AEG in
At productronica 1977, LACH DIAMANT® demonstrated for the first time PCD tools for cutting circuit boards
no. 4, November 2023
7

cover story
And then, it sparked
The turning point of this initially negative
story came one year later, October 1978, as an
advertizement for a spark eroding machine
of the Frankfurt-based company MATRA.
Never heard of such a thing. Spark machine?
But then I remembered the words of my father,
who mentioned several times that electricity
always is a factor when grinding natural
diamonds on obligatory cast wheels.
“What the heck?” I said to Gerhard Mai, our
newly appointed master of PCD production,
a former cutter of natural diamonds, trained
at LACH DIAMANT®. “Let’s take a look
at this…”
Wire machine, type EDM 1979/80, during the processing of
polycrystalline cutting materials (re-enacted photo with Dirk Rüttgers)
Seligenstadt: a Swiss machine, manufactured by Amacher. Three processes
could be executed on this small precision mini machine of the HAMBA type:
cutting, scoring and edge processing. Excellent. Registered for the fair. Internal
work order for the three needed PCD tools or saws, respectively. Only
the production had some concerns: “How are we supposed to sharpen these
rotating tools? It will take forever….” In fact, for twelve teeth, for example,
we needed 35 hours of grinding time! But I thought, and said it as well: “You
will manage, so far, you have always come through with an idea.”
At first, productronica 1977 was a great success for LACH DIAMANT®.
Due to an increased demand for electronic circuit boards, visitors from the
great and famous companies gathered around the little Amacher machine to
admire this precise, selective and dust-free cutting of PCB, the base mate rial
for circuit boards.
To this day I remember the gentlemen from Siemens and NCR who immediately
thought of diamond saws with a diameter of 300 to 350 mm for machining
packages, and spontaneously ordered samples for further testing.
It could have been so nice. Even in 1977 cutting circuit boards could have
been more efficient. If…, yes , if the following had not happened: “Boss, we
are really doing everything for you, but we can only focus on either producing
scorers and saws for circuit boards, or we can continue to serve customers
like Bosch and Kautt & Bux with commutator diamonds.” For then that
was it, regarding the rotating PCD tools. “Grinding” technology with a result
of 35 hours for 12 teeth made its point very clearly. During the following
12 months I had more than one unpleasant task. Engineers and industry
experts, “hot” for this successfully introduced new technology, overwhelmed
me with questions, and accused me of holding back this technology
for whatever reason. In short: they were miffed.
Whereas the only culprit was this beastly polycrystalline synthetic diamond
material; even experienced cutters of natural diamonds surrendered
to it. Over and over we were pondering how we could conquer this invincible
stuff better, meaning faster.
Quickly we had made an appointment with
Mr. Schreiber and Mr. Becker of MATRA.
“Yes, stop by with your extremely-hard-togrind
carbide, we will see what we can do…”
We prudently had failed to mention that this
carbide was in fact PCD.
I clearly recall how Mr. Becker greeted us at
the entrance and lead us into a hall with rail
access. Left and right from the entrance were
some, for me at that time, unidentifiable machines.
We stood in front of a machine that I
would describe as some sort of “sinking machine”.
The PCD sample we handed over for
the “spark test” was carefully mounted and
disappeared in a “brew” which I now understand
as a kind of dielectric fluid. The power
was switched on. I could tell from the look on
Mr. Becker’s face that he expected our PCD
to show a reaction. We took turns to examine
the probe under a magnifying glass to
see whether anything was changing. Nothing
happened, not even for the next five minutes.
“Well, I am sorry, apparently nothing works
with this carbide…” they said regretfully.
“Well then, it was worth a try,” we thanked
them and were already on our way out of
the hall, when I discovered a machine in the
far right corner. It looked slightly different,
mainly because of an additional “tower- like”
structure. “What kind of machine is this,” I
heard myself asking, “a wire machine, it’s a
similar machine,” was the answer, “alright,
since you are already here and if you want to
we can try another experiment. Let’s go over
there, but I have to tell you right away that it
contains a profile for one of our customers.” I
only said “that doesn’t matter.” So the sample
was mounted again – it immediately started
to brew – and it worked right away, in the truest
sense of the word. The hot wire actually
cut the described profile out of the PCD – and
formed it. This visible success surpassed all
8 no. 4, November 2023

cover story
of our expectations. This “beastly material” had finally been
conquered for the first time.
A technical sensation
While I am writing this, 45 years later, I am asking myself
what did we think at that moment. Were we actually aware of
the ramifications of this discovery?
Today I interrupted Gerhard Mai, now retired, with this
question for a few long minutes. Of course we had witnessed
how the force of spark erosion had profiled a small piece, in
a bubbling brew, of polycrystalline diamond (PCD) cutting
material, i.e., it was processed. Without extensive grinding – if
the latter would have been possible at all. Were we thinking
of the saws and milling tools, produced for the productronica
one year ago (in 1977), with an enormous expenditure of 35
hours of grinding time? Or did we even consider the possibility
that our suppliers, General Electric or DeBeers (status of
1978), could (not only) provide us with elaborately produced
60 ° or 90 ° segments but instead with PCD blanks, so that we
could wire-cut the desired segments ourselves? Did we anticipate
the production of shaft angle PCD tools such as milling
tools, saws etc? Mr. Mai and I agreed: no, we had not thought
of any of this.
I was then driven by the idea to immediately register this
discovery or this process for a patent; we did this on the
same day, on October 13 th , 1978, with our patent attorney
Dr. Strasse (✝) in Hanau. Today Dr. Stoffregen, who later took
over the law firm, still remembers this day very clearly.
For the 100-year anniversary of LACH DIAMANT® he
wrote (in extracts): “Look into the patent register, you can
find more than 100 patent rights registered for your company
within the last 50 years, and almost half of them name Horst
Lach as the inventor. One of them I want to particularly
single out today since it also has an anniversary. As a young,
newly licensed patent attorney, I was charged with the task
to draft the paperwork for an invention of young Mr. Horst
Lach; it had to do with processing polycrystalline diamonds,
a beastly, difficult-to-work with material as he put it. The first
patent application for your invention was filed at the German
patent office on October 13 th , 1978, exactly 45 years ago,
and registered at the European patent office exactly one year
later, on October 13 th , 1979. The publication reference number
is 0010276. This low number indicates that you were one
of the earliest registrants at the European patent office. The
main claim of this patent is worded as follows: procedure for
electro erosive processing of polycrystalline synthetic diamonds,
characterized by the use of spark erosion for the production
of user-defined profiles. This short description indicates
that this patent has an extensive scope of protection.
The patent claim ensures a simple way to process the beastly
PCD material, a revolutionary invention, first for tool manufacturers
in the wood and composite industries, but later
was deployed wherever rotating tools are used, such as in the
automobile and aircraft industries.”
A conversation with Wumm
Our team, Dipl.-Ing. G. Hobohm, Mai and Wagner, all sworn
to utmost confidentiality, had not been able to think about
The unleashed spark for cutting polycrystalline diamond
and CBN materials
how to proceed from here, when an unexpected phone call
suddenly took the initiative away from us. The caller was Mr.
Denker, now with Resopal in Grossumstadt (former Römmler
GmbH). He immediately came to the point. “Mr. Lach, I read
that you introduced diamond milling tools at a tradeshow (he
meant productronica 1977 in Munich)”. I confirmed this. Mr.
Denker continued: “We currently have a problem; can you
build a profile milling cutter for us?” In an instant I was wide
awake. Only 14 days ago I would have answered with a “no, I
am afraid not”, but now? Most likely, I answered with a longdrawn
“yes!” and so Mr. Denker proceeded: “what we call
an American milling cutter, with a profile for a postforming
worktop with a cutting width of 45 mm, and a tool diameter
of 160 mm”. When the dimensions were mentioned, I
responded with “BUT – at the moment we are not yet ready
for this size in our production.” Denker: “that does not matter;
we will send you two Leuco milling cutters with carbide
cutting edges, and you simply un-braze them and put your
diamonds on top.”
That is how the short conversation run, but yet it was pivotal
for the future of this cutting material, now still in its fledgling
stages. For all of us, tool manufacturers, users, and for
the producer General Electric.
Under Pressure
The management of GE Superabrasives in Worthington/Ohio,
ranging under the department “Filament Lamps” in the
no. 4, November 2023
9

cover story
be profitable at that time. The number of items
sold were too low.
The general manager of GE Superabrasives,
Louis Kapernaros, who would become a good
friend of mine in later years, talked very
openly with me about this. For at least another
seven years after the first market launch
(1973), it was a laborious process to cut the
PCD cutting edges out of pressed PCD blanks
with electroplated cutting wheels. As I remember,
the length of the available cutting
edges was 6.6 mm and was increased to only
13.2 mm in the following months – thanks to
new presses.
Due to a lack of efficient technologies for
processing/forming this superior cutting material
(compared to carbide), marketing of
PCD tools remained limited to single-tipped
turning tools and inserts; this was simply too
little to generate higher sales and production
numbers in order to gain greater acceptance
within the cutting industry.
1979/80: worldwide first manufactured PCD diamond milling cutter for
profiling plastic-coated chipboards for use in wood/plastic processing machines,
double-end profiler, with up to 350 times better durability
company’s hierarchy, came under a lot of pressure at that time; despite off all
efforts and investments, GE Superabrasives had not yet managed to produce
the same profit margins as a simple “pin” manufacturer.
In short, the pressure was so great that the “Filament Lamp” department
threatened to part with the subdivision “Superabrasives”. I understood why
sales of polycrystalline inserts (PCD) under the GE “compax” label could not
Furthermore, GE Superabrasives was in
direct internal competition with GE subsidiary
“Carboloy”, a carbide manufacturer with
most likely little interest in polycrystalline
diamond cutting materials.
A sudden turning point in sight
This phone call and quasi the first order for
the production of two PCD with 45 mm cutting
width should revolutionize the mass production
of entire industries. Starting with the
wood and plastics processing industry (for
example the resopal factory), and followed by
automobile, aircraft, and wind energy industries
as the now leading processing industries
for aluminum, fiberglass and carbon fiber reinforced
materials and plastics.
The appropriate and superior tools of the
trade were now discovered and available – the
spark erosion!
More history and interesting stories will follow in the next edition of the
100-year anniversary series of LACH DIAMANT®
By the way, the first delivered PCD milling
cutters were six (!) months in use during
3-shift operation. Directly comparable carbide
tools had to be uninstalled and sharpened
by an expert technician after every shift.
From the beginning on the PCD milling
cutters had 350 times more durability than
previously used carbide tools. Since it was
possible to resharpen the PCD milling cutter
as well, it could be used for approximately
three to four years.
Yours, Horst Lach
further information: www.lach-diamond.com
10 no.4, November 2023

materials & tools
“AI is not an add-on job”
At EMO 2023
precision tool manufacturers
showed how
machines, systems or
components can be
cleverly equipped with
AI in the future.
Research at the
Fraunhofer Institute for
Production Technology
IPT in Aachen, Germany,
proves that AI can advance
machining. The
Dr.-Ing. Maik Frye
researchers were able to
demonstrate, for example,
the potential for users to reduce the measurement effort
required in milling processes by up to 50 % thanks to the
use of AI. This increases value creation immensely. When
it comes to introducing AI in manufacturing companies,
Dr.-Ing. Maik Frye, group leader for production quality at
the Fraunhofer IPT, sees three hurdles that need to be overcome,
according to him. “The biggest hurdle, at least currently,
is people. Many don’t trust the models and are afraid
that data could fall into the wrong hands or are reticent to
engage with the new technology.” In addition the adoption
of AI depends on the data base. “Most of the time the
necessary data is not available in the required quality,” says
Frye, who helps companies implement AI. “In many cases
companies have to generate the appropriate database first
on the way to implementation.” The third hurdle: “AI is not
an add-on job,” Frye points out. Companies should create
their own staff capacities for this in order to be able to
accompany the process in a promising manner.
Using AI to tackle the shortage of skilled workers
Aware of the need for additional resources, the Paul Horn
carbide tool factory in Tübingen started the introduction of
AI from the very beginning. “We have created directly capacities,
whose focus is on AI,” says Markus Kannwischer,
head of technology and member of the management team
at Paul Horn. Currently various systems, such as for grinding,
are being tested. In the in-house milling shop, on the
other hand, AI is currently already being implemented. The
goal is to increase process reliability and to fully utilize the
cutting tools until the end of their service life. According
to Christian Stark, development engineer at Paul Horn,
employees will also appreciate AI in the future. “AI will
help them to better understand the complex interaction of
processes and receive recommendations for process optimization,”
Christian Stark looks into the future. “This is a
big plus in times of shortage of skilled workers, as we can
optimize setup times and help new employees make the
best possible decision faster.” This brings the big goal of
equipping the entire group’s machines with AI within
reach.
AI-capable sensory clamping technology
The sensory clamping technology of the ROEMHELD Group
from Laubach is already AI-capable today: this is because the
sensors provide all data in the correct format and enable the
overall system to intervene in the process and, if necessary, adjust
machining parameters. “We are still at the beginning in
terms of the possible applications of AI,” says Philipp Ehrhardt,
managing director of Römheld GmbH, Friedrichshütte. According
to him the potential is huge, especially with a view to
automated, autonomous manufacturing. Visitors of EMO 2023
could find out how intelligent the solutions from the Laubachbased
company already are, by taking a look at a demonstrator.
Various clamping elements equipped with extensive sensor
technology for Industry 4.0 applications were there in use. The
STARK.intelligence sensor system is one of them. It records
the entire process sequence, keeps an eye on maintenance
and allows end-to-end digitization and communication of all
clamping devices. The zero-point clamping systems connected
to this solution measure paths, positions, temperatures and
pressures in real time and provide information about the “state
of health” of the clamping devices. The sensor system can also
be successfully equipped with AI. Ehrhardt is certain, “It’s just
a matter of time before AI becomes a no-brainer.”
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materials & tools
CNC diamond wire saws
to cut 2D contours in glass
The German electrical discharge machine supplier
Ageltech GmbH has also a series of CNC diamond wire
saws in its range, the MK series, and focuses on an outstandingly
attractive price-performance ratio.
The technology has a wide range of applications, the gen eral
rule is: “Diamond wire cuts everything”. CNC also enables the
creation of contours and 2D free forms, of course also simple
straight cuts such as for samples or discs, e.g. for R&D or
quality verification. Wire generally allows a minimal cutting
gap, for example around 0.2 - 0.5 mm. The possible uses are
very extensive and include most non-conductive materials,
e.g. glass, ceramics, crystals, CFRP, stone, sandwich materials,
composites or even highly porous AM materials and
honeycombs. In terms of shape the possibilities range from
simple disks and cuboids or cylinders to more sophisticated
shapes such as special seals or undulated contours to complex
structures such as name lines or logos.
The saws are suitable for the production of discs, cuboids,
cylinders, ornaments, repair parts and also for the economical
separation of the 3D print pieces from the building
boards. Due to the simple medium of diamond wire, which is
operated with filtered city water and an additive, only low operating
costs are incurred. There is the possibility of test work
in advance on the specific workpiece or the ordering of service
contract works.
Experience in practice
The possible uses are very extensive, because diamond is the
hardest element and therefore cuts everything except tough
and ductile materials that clog the wire. Due to the competition
with EDM saws, diamond wire is more recommended
for non-conductive materials. Compared to the band and
disc saw blade, the wire can score points with its smaller kerfloss
and even sawing performance in all directions around
360 °, which, however, is also associated with a significantly
lower cutting performance. The 360 °-capable cutting is made
possible by a CNC control of the X and Y axes, which move
the tool table in increments of 1 µm. A more precise infeed
does not make sense, because even with the minimum wire
cutting height of 200 mm of the smallest saw MK200, there is
a wire deflection in the range of well over 1 micron, especially
with 2D movements.
MK200 CNC diamond wire saw
Simple sawing of straight lines for samples
The MK series ranges from the MK200 model with machining
options for workpieces of 385 x 495 x 200 (h) mm³
and cutting lengths of 200 x 250 mm in several increments
to the MK500 model for large workpieces of
650 x 1000 x 600 (h) mm³ and cutting lengths of 500 x 630 mm.
All machines are designed for industrial use and dimensioned
accordingly. The cutting line can be created, for
Complex 2D contour cut with MK200
12 no. 4, November 2023

materials & tools
example, simply by transferring a DXF file from AutoCAD® and correcting
it by entering an offset – by reason half the wire thickness. With this
the outer edge of the wire runs along the outer edge of the workpiece of
the drawing. The course of the cut can be followed on the monitor, the
elapsed cutting time and the expected remaining time as well as other
helpful parameters are displayed.
The technology is tried and tested and uses diamond wire as the cutting
medium, which has matured and is inexpensive after decades of development,
resulting in low operating costs from 2 - 3 Euro/hour which originate
from: wire, water and an additive for cooling, anti-oxidation, lubrication
and particle as the cheap consumables, and 4 wire guide rollers and
an occasional exchange of ball bearings define the usual, also cheap wearing
parts. A significant reduction in unit costs can often be achieved using
batch processing by assembling several workpieces together (stacking).
A wide range of fixing options and a rotation unit for faster sawing
of discs or for surface improvement, as well as a suitable range of diamond
wires and consumables and spare parts complete the offer. Finally,
the specially developed CNC system offers a number of advantages:
on the one hand, it enables quick reactions such as update options for
new requirements, on the other hand it is Linux-based and thus also
reduces the risk of viruses. For different safety standards the MK series
can be equipped with various protective housings and automatic switchoffs,
right through to a laser beam cage. Basic users can learn how to
operate and set up the machines quickly. Ageltech offers own service
for Germany, Austria and Switzerland, as well as for most of the rest of
Europe.
Your
Automation
Partner
When Precision Motion
Control Matters
Outstanding price-performance ratio
According to Europe sales manager Alexander Postl, Ageltech deliberately
focuses on an outstandingly attractive price-performance ratio. In
terms of price, international sourcing contributes to the lowest purchasing
costs. Purchasing large quantities in a network and streamlining the acquisition
processes contribute to further cost reduction. The CNC system
is based on a specially developed solution. And this is where the quality
side is reached: Ageltech checks and revises weak points in each individual
machine and assembles all other components in Germany according to
German standards. There is a 100 % initial quality control.
Having its own R&D team in the group enables quick reactions to customer
requests and continuous development of the CNC diamond wire
saws. The last point is the free best advice principle, which means selection
according to the customer’s requirements and thus helps to avoid unnecessary
and overpriced machines and options. On request, the customer
receives a customized production process together with his saw, including
the transfer of know-how. This is particularly valued by market participants
from outside the industry who are building up another field by
expanding their range of products and services.
Conclusion
Ageltech’s CNC diamond wire saws are robust machines with a sensitive
tool and offer an outstanding price-performance ratio thanks to
optimized purchasing structures, own CNC system and German revision,
assembly and quality control. With the CNC diamond wire saws of the
MK series, laboratories and institutes can carry out their R&D tasks such
as probes and samples, as well as manufacturing companies can produce
their prototypes and small series and the industry can also produce their
large series.
further information: www.ageltech.de
FIND YOUR
SOLUTION

materials & tools
The first PCF standard for cemented carbide
On the occasion of EMO 2023 in Hanover,
CERATIZIT has kicked off the introduction of the first
Product Carbon Footprint standard (PCF) for carbide
products. Since September 18 the PCF classification of
the first wave of products is displayed in the shop and
on all invoices. Detailed information on the PCF of the
corresponding products can be requested as an additional
service.
“The start of the systematic introduction of PCF figures in
our product portfolio is an important milestone. Not only
do they allow our customers to calculate their own corporate
carbon footprint more accurately. The PCF figures also
provide the basis for setting up a strategy to reduce their own
emissions,” executive board spokesman Dr. Andreas Lackner
commented on the launch of CERATIZIT’s PCF offering.
Different service levels
CERATIZIT’s service offer around the PCF includes several
service levels. For all products already included in the
range of services, the PCF class is displayed in the shop and
on the invoice at no extra charge. This alphabetical classification
with six classes from A to F allows to know and assess
a product’s footprint with a single glance. The second option
includes an average PCF value in kg CO 2 e/kg product as well
as a summary overview of the total carbon footprint related
to the listed products and volume manufactured and supplied
in a customer-defined time period. The most comprehensive
service level provides customers with detailed PCF information
on every purchased product for which the data is available.
At the start this information will be offered only for certain
products. But the goal is to gradually expand the share
and ultimately provide PCF information for all products.
upGRADE products always come with
PCF information
Products from the upGRADE family, which are made from
100 % secondary raw materials and have a particularly low
PCF, also take on a special position. With these products, detailed
PCF information is already included in the purchase
price. The CT-GS20Y grade for rods for cutting tools and
the KLC20+ grade for wood working are made from strictly
selected secondary raw materials and combine premium
performance with a particularly low PCF, which is on average
around 60 % below the PCF of corresponding standard
CERATIZIT grades and places them in PCF class “A”.
Externally verified calculation model
The calculation approach is in line with the ISO 14067:2018
standard and has been critically reviewed by a third party,
denkstatt, a member of Inogen – Environmental Alliance
(https://denkstatt.eu/).
In-depth information about the PCF model
on request
Detailed information on the model behind the Product Carbon
Footprint calculation will be available in the coming
weeks but can already be requested via the link on the landing
page (https://www.ceratizit.com/int/en/sustainability/pcfclassification.html)
and directly by email to sustainability@
ceratizit.com. Customers, partners and market companions
and all others are all invited to take a look at the model and
adopt it if they wish. Only by working together will it be possible
to lead the hard metal industry into a more sustainable
future.
further information: www.ceratizit.com
14 no. 4, November 2023

materials & tools
Ultra-hard premium cutting materials for Europe
The South Korean company ADICO produces and distributes
PCD (polycrystalline diamond) and PcBN (polycrystalline cubic boron
nitride) high-performance cutting materials in application-specific
grades, that serve as the starting material for the production
of high-quality cutting edges and tools. They are used worldwide in
demanding machining applications, including in the automotive,
aerospace and woodworking industries.
In order to better serve these customers in Europe, ADICO is expanding its
European sales activities. Philipp Homann, an experienced sales expert, has
taken over the management of European sales as sales director Europe. He
has more than 20 years of experience in international sales of PCD and PcBN
cutting materials.
ADICO was founded in 1999 by the two developers Dr. Hyun Sam Cho
and Kyoungryoul Han as an independent manufacturer of ultra-hard cutting
materials for the industrial location of South Korea. The company gradually
established itself internationally and has made a name for itself as a premium
supplier of PCD and PcBN. Today its customers include well-known international
tool manufacturers for the metal- and wood-cutting industry. The
strengths of the South Korean cutting material supplier lie above all in the
high quality, the production within the lowest tolerances and the application-specific
cutting material development.
Exterior view of the ADICO company
“We develop the perfectly adapted cutting
material made of PCD or PcBN specifically
for our customers’ applications,” emphasises
Philipp Homann. All customers in Europe
can now increasingly benefit from this.
further information: www.adico.kr
New end mills for volume machining of
aluminum materials
The alu-cut “Aerospace” WF series from FRANKEN represents
an end mill family made of carbide and HSSE-PM for volume
machining in aluminum materials. The alu-cut “Base” product line
is supplemented by new diameters and lengths.
The new high-performance tools of the alu-cut “Aerospace” WF range were
specifically developed for the process-reliable volume machining of aluminum
and copper alloys in the aerospace industry. The uncoated version is designed
to machine wrought and cast aluminum alloys with a silicon content
of up to 7 %. There are also GLT-coated versions available for cast aluminum
alloys with a silicon content of up to 12 % and copper alloys.
A newly developed geometry of the chip divider enables low-vibration
roughing and finishing of aluminum. The WF cutting edge geometry for
aluminum machining is available with and without corner radius, as well
as in two length versions. The end mills have an internal coolant-lubricant
supply with radial and axial outlet (ICRA).
New lengths and diameters for alu-cut base
The alu-cut “Base” product range includes high-performance end mills with
different geometries for universal use in aluminum and copper alloys. Volume
machining in aluminum can be carried out with all available variants
– depending on the machine stability. In addition these tools with finishing
teeth can achieve dimensionally accurate and high quality surfaces
without losing flexibility. The end mills are fitted with a chamfer, the product
line is supplemented by different variants with corner radius so as to always
The alu-cut “Aerospace” WF end mills from
FRANKEN are specialist tools for volume
machining of aluminum and are designed
for use in the aerospace industry
have the suitable tool available for the specific
requirements on the component. The existing
geometries are supplemented by the diameters
14 and 18 mm. Additionally there are two new
lengths: 3.5 x D and 6 x D.
further information: www.emuge-franken.com
no.4, November 2023
15

materials & tools
Update on live tooling
A review of this machining method, the basic concepts and
some exciting developments in the technology
written by Preben Hansen, president Platinum Tooling Technologies Inc., Prospect Heights, Illinois, USA
Live tooling, as a component on a lathe, is specifically
manipulated by the CNC to perform various
milling, drilling and other operations while the workpiece
is being held in position by the main or sub spindle.
These components, whether BMT or VDI, are also
called driven tools, as opposed to static tools, that are
used during turning operations. All live and static
tools are built per the machine tool builder’s specification
for each of the various models they produce. A
key to running a successful job shop or production department
is to partner with a supplier who can meet
the tooling needs for all or most of the machines on
your floor.
Most often, live tooling is offered in standard straight and 90 °
angle head configurations with a wide range of tool output
clamping systems, including ER collet chuck, arbor, Weldon,
Capto, whistle notch, hydraulic, HSK, CAT, ABS and a variety
of custom or proprietary systems developed by the many
suppliers to the industry.
When the need arises for a new machine tool, careful consideration
should be made to determine which live tools
are appropriate for your application. While a standard machine
tool package will help you get started, it is important
to anticipate job and volume changes, as well any unforeseen
A typical ER collet adapter changing system allows
for greater flexibility and cost savings
machining challenges from the beginning, in order to avoid
machine downtime. This short article is meant to give you a
set of parameters to consider when evaluating the live and
static tooling to use in your shop or production department.
Simply stated, you need to do as much evaluation of your process,
when determining the proper tooling to be used, as you
did when you evaluated the various machines available for
purchase. This fact is often overlooked and that can be a critical
error, in the long run.
Your examination can range from the simple (external vs.
internal coolant, for example) to the sublime (adjustable or
multi-spindle configurations) to the custom tool, that may be
required and built to suit your special application. Finding a
supplier who has an in-house machine shop for the preparation
of special tools is a great value-add.
The combination of taper roller bearings and spindle bearings
are best for live tool rigidity
Tool life is the product of cutting intensity, materials processed,
machine stability and, of course, piece parts produced.
Two seemingly identical job shops can have vastly
different tooling needs because one is automotive and one
is medical, or one specializes in the one-off and low-volume
work, while the other has a greater occurrence of longer running
jobs. The totality of your operation determines the best
tooling for the machines being purchased.
16 no. 4, November 2023

materials & tools
Bearing construction and the resulting spindle concentricity
drive the life of any tool. You might find that just a 10 - 15 %
greater investment in a better design can yield both longer
lasting cutters and consistently superior finish on your products.
Of course the stability and rigidity of the machine tool
are always critical factors. Bevel and spur gears that are hardened,
ground and lapped in sets are best for smooth transition
and maximum torque output. Taper roller bearings are
consistently superior to spindle bearings in live tool milling
applications, so look for a combination system to get the
highest rigidity possible. Also look for an internal vs. external
collet nut, so the cutting tool seats more deeply in the tool,
as superior performance will result.
Likewise, high pressure internal coolant might be desirable.
Look for 2000 psi capabilities in 90 ° tools and 1000 psi
in straight tools.
You need to ask another question, namely, is the turret
RPM sufficient to handle the work to be done? It’s possible
that a live tool with a built-in speed increaser, often called a
speed multiplier, would be helpful. Would it be beneficial to
move secondary operations to your lathe? Gear hobbing can
be accomplished in this manner, as can producing squares or
flats, through the use of polygon machining.
Standard live tooling most often is best suited to production
work, where the finish, tolerances and cutter life are critical,
while quick-change systems may be better suited to the
shop producing families of products and other applications
where the tool presetting offline is a key factor in keeping the
shop at maximum productivity. It’s a given in our industry
that when the machine isn’t running, the money isn’t coming.
This opens the discussion of long-term flexibility and
it’s the most often overlooked consideration in buying live
tools. You might ask, what work do you currently have in the
shop and what work will be coming in the future? The overall
economies of a changeable adapter system on your tooling
may be a consideration not often made when your focus
is centered on the machine being purchased. Dedicated tools
Multi-spindle tool brings improved cutting capacity
to your lathe
Shown here is a standard BMT cross working tool
for large families of products may often be desirable for some
applications, but do consider whether a flexible changing system
would be more appropriate. Talk to your tooling supplier
for the various options, before making that determination.
If standard ER tooling is suitable for the work, there are
many good suppliers. It is important though, to pay close attention
to the construction aspects noted above. For a quickchange
or changeable adapter system, there are fewer suppliers
in the market, so seek them out and be sure they can
supply the product styles you need for all your lathe brands.
Now, an application example showing clear evidence of the
value of testing live tool performance…
One company was performing a cross-milling application
using an ER 32 output tool on a Eurotech lathe, running
10 ipm at 4000 rpm. They were making three passes with
a cycle time of 262 seconds and were having difficulties with
chatter on the finish, while producing 20,000 pieces per year.
The annual cost of the machining was over $ 130,000. By
using an alternative live tool with an ER 32AX output, internal
collet nut design, with the same parameters, they were
able to produce the part in a single pass with a smooth finish
and cycle time of just 172 seconds. Over the course of the
year, this yielded a cost savings of $ 45,000, approximately
20 x the cost of the tool. The bottom line is the bottom line, as
the accountants tell us.
In the end, you may not need a universal adjustable tool or
a multi-spindle live holder or even a quick-change adapter
system, but do consider all these options. Talk to your machine
builder and several tool suppliers, plus the most important
people in this equation, your shop personnel, as their
input is invaluable to keeping you up and running in a profitable,
customer-satisfying scenario.
further information: www.platinumtooling.com
no. 4, November 2023
17

materials & tools
New high-performance grade for thread whirling
nent quality. The carbide grade is available for
all standard Horn thread whirling systems.
Furthermore, in-house coating enables fast
delivery times.
The carbide grade SG3P is available for all standard
Horn thread whirling systems
SG3P is the name of the newly developed Horn high-performance
grade offering the user new possibilities in terms of performance
and tool life when whirling medical screws. The new carbide
grade also enables shorter cycle times for thread production thanks
to higher cutting values, including when processing materials that
are difficult to machine.
The combination of an ultra-fine grain carbide powder and the high temperature
resistant coating results in high process reliability and better compo-
The production of bone screws must necessarily
be carried out using a metalcutting
process, as the material for this type of
screw must not be compressed, as is the case
with thread rolling, for example. Particularly
titanium, which is mainly used in the human
body because of its good biocompatibility,
tends to burn when compressing the material
too much. As a machining process, conventional
thread whirling has been done for many
years, being a process mostly used on Swisstype
lathes for manufacturing bone screws, on
a larger scale for the production of threaded
spindles. In the process the rapidly-rotating
whirling head is positioned eccentrically to
the workpiece axis in front of the guide bush
of the sliding-headstock lathe and the slowly
rotating workpiece is guided into the whirling
head with an axial feed movement.
further information: www.horn-group.com
High performance in stainless steels
Horn has developed a new, solid carbide milling cutter range especially
for machining stainless steels. The tools are for milling
stainless materials in the food, chemical and pharmaceutical industries
as well as the precision engineering and watchmaking
industries.
In addition, due to their geometry and good chip breaking, the milling tools
are suitable for machining numerous other materials. Due to the precise
combination of the substrate, the macro and micro geometry as well as the
IG3 coating, the milling system exhibits high performance and long tool life.
The coating in particular offers high temperature resistance for machining
steels alloyed with chromium, nickel and molybdenum.
Horn offers the solid carbide milling tools from stock in two types. The
DSHPR variant is suitable as both a finishing and a roughing tool. The geometry
is also adapted for trochoidal machining and plunging. The DSR type,
with its very sharp cutting edge geometry and short design, is suitable for
very small parts and unstable clamping conditions, such as in the medical
and watchmaking industries. In the DSHPR line, all tools are available with
four teeth and in diameters from 2 mm (0.079") to 20 mm (0.787"). Horn
offers the DSR variant with three teeth in diameters from 1 mm (0.039") to
10 mm (0.394").
further information: www.horn-group.com
Due to the precise combination of the
substrate, the macro and micro geometry as
well as the IG3 coating, the milling system
exhibits high performance and long tool life
18 no. 4, November 2023

materials & tools
PCB circuit boards
Cutting –scoring –milling with superior diamond and solid carbide tools
Presented by LACH DIAMANT for the first time in 1977 at
productronica, the portfolio of diamond and carbide tools showcased
at this year’s productronica will captivate visitors with a superior
modern tool range, especially designed for efficient circuit board
production, for the world’s leading manufacturers of electronics.
An example: “Depanelling saws” for stress-free cutting of circuit boards in
multiple production, with highest precision; cutting widths as of 0.3 mm are
achieved. Toothed tools are available with an ultrafine pitch of up to 1.4 mm.
Scoring tools: initially only single-layered boards could be scored effortlessly
with solid carbide tools, but since then there have been major technological
developments. Today fiberglass, ceramics and hybrid materials
are being used; new production technologies made it possible for LACH
DIAMANT to develop a line of high-performance PCD “DreboBlueCut”
scoring saws with superior durability. As usual, all LACH DIAMANT standard
scoring saws, special models and saws with any desired edge geometry
are immediately available or can be delivered on short notice. Hybrid materials
and further challenges: as a global player in the tool industry, LACH
DIAMANT– founded in 1922 – develops and manufactures machining tools
which all leading international electronics manufacturers find indispensable
for efficient production since the first presentation at productronica 1977.
LACH special cutting saws for
stressless depanelling
LACH DIAMANT is perfectly equipped
and prepared, even for new challenges – like
modern hybrid materials, developed with
most diverse properties – electroconductive,
heat-resistant, but also with insulating and
heat-dissipating properties etc.
further information: www.lach-diamond.com
Newly developed diamond and CBN grinding wheels
for previously impossible grinding tasks
A grinding wheel with a metal bond for deep grinding – hitherto
almost unthinkable. For the first time newly developed bond variations
are available for profiling during the deep grinding of carbide,
high-alloyed steel and ceramics in mass production.
What was, up to now, only possible in time-intensive conventional grinding
procedures or with several diamond and CBN grinding wheels, is now
accomplished with only one profile grinding wheel known as “contour-profiled”:
“One for everything“.
The innovative metal bond allows for something never thought possible:
contour grinding from the solid – and with profile depths of up to 15 mm(!),
e. g. bottom blades or profile blades – there is absolutely no impact on tool
life, even at full feed rate. The result: repeatable precision profile cuts in mass
production. The advantage is obvious: significant reductions to a fraction
of the original total cost. The highly developed “contour-profiled” grinding
wheels can even be re-sharpened: for this purpose, LACH DIAMANT
developed a special method which can produce high-precision concave and
convex profiles from 2 to 4 µ.
further information: www.lach-diamond.com
The unique metal bond of the
“contour-profiled” diamond and
CBN grinding wheel makes the process
of deep grinding significantly easier
no.4, November 2023
19

materials & tools
Solutions for
Advanced Materials
Advanced Materials is a much-used term, but what
does it mean? At Leitz it means materials that are not
made of wood, or wood-based materials, and also have
completely different properties in machining than are
common in woodworking. These include materials for
façade cladding, insulation materials, aluminum, plastics
and composite materials. A broad and constantly
changing field of modern materials, some of which
also requires new machining processes – for which
Leitz naturally always develops the appropriate complete
solutions consisting of tools and services.
Whether as façade cladding for buildings, in the automotive
industry or in aviation – Advanced Materials are extremely
versatile in their application and demanding in their processing.
However, the functional materials are usually more homogeneous
than wood, sometimes very abrasive and it is not
always possible to use a standard tool for machining. In the
field of plastics and composite materials, a further challenge
is the increasing mix of unknown materials, which must be
examined in detail before machining.
Permanent exchange as the cornerstone
for processing recommendations
This makes it all the more important for Advanced Materials
to offer a complete package consisting of competent advice,
individual tests on the material and a wealth of experience in
machining. In close and permanent exchange with users and
machine manufacturers, Leitz specialists examine the desired
materials in order to optimally coordinate processes and
tools and then use this information to create machining recommendations
for the customer. In the case of newly developed
materials or a material mix, machining tests in the Leitz
Technology Center are also elementary. Based on the knowledge
of the specialists from Oberkochen, existing tools are
then either modified or even newly developed.
Optimum solutions for challenging materials
Leitz is presenting a tool that is used, among other things,
for narrow-side machining of HPL materials and fiber-reinforced
plastics. The Diamaster PLUS Z2 router has a negative
axis angle for qualitatively perfect, tear-free edges when
joining and grooving. It has a short, stable cutting edge and
is therefore very suitable for most common panel thicknesses.
As these compact laminates are mostly made of melamine
and phenolic resin impregnated papers or cellulose fibers,
this usually leads to high tool wear. The Diamaster PLUS Z2
router bit therefore has a diamond basic cutting edge, which
ensures a very long service life and thus higher productivity.
In addition, the tool can be resharpened up to eight times.
The Diamaster
WhisperCut
prismatic
rebate cutter
head operates
significantly more
quietly and with less
energy consumption
than conventional rebate
cutter heads
The BrillianceCut circular saw blade for processing acrylic
glass has proven itself exceptionally well on the market.
When sawing this material, scoring, melting or chipping often
occurs on the edge of the sheet. The consequences are
additional work steps to prepare the edge for gluing, polishing
or scarfing. Thanks to the innovative tooth geometry of
the BrillianceCut, users achieve perfect cut surfaces in finished
cut quality already during the splitting process, eliminating
additional work steps, allowing much more efficient
work. Plastic-filled laser ornaments incorporated into the
circular saw blade not only reduce noise, but also ensure increased
running smoothness and stability. The circular saw
blade also has a long service life thanks to the stable tooth geometry
and can be resharpened up to 20 times.
In architecture and industry, aluminum composite panels
are often used when special requirements are placed on the
stability and formability of building elements, on the durability
of surfaces or on weight reduction. The machining of these
materials is a real challenge in many cases. The Leitz range of
tools for processing aluminum composite panels is impressive
in its versatility and performance. For example, carbide
or diamond-tipped circular saw blades for perfect cutting
quality when cutting panels. With the RazorCut Plus circular
saw blade and its high cutting speed the productivity is increased.
Diamond-tipped circular saw blades have a particularly
long service life. The very durable Diamaster PRO router
bit is also diamond-tipped and has a long service life even
with difficult materials. Very high feed rates are possible, reducing
the machining time of the panels and thus increasing
the user’s productivity significantly. The Leitz range for aluminum
composite panels is rounded off with the Diamaster
WhisperCut prismatic folding cutterhead. This tool works
much more quietly and saves energy. The tool, which can be
resharpened several times, is especially suitable for V-grooves
with 90 ° and 135 ° and delivers perfect cutting results.
Leitz knows the importance of new, challenging materials.
At Advanced Materials the specialists from Oberkochen are
once again demonstrating their adaptability and high level of
innovation in order to provide their customers with individual
and optimal solutions for greater efficiency, quality and
productivity.
further information: www.leitz.org
20 no.4, November 2023

For each titanium the right drill
materials & tools
Mikron Tool presented the new CrazyDrill Cool
Titanium ATC/PTC series at EMO 2023 in Hanover,
which ensures maximum process reliability when
drilling pure titanium and its alloys.
The high-performance material titanium poses a chip removing
machining challenge. Also, not all titanium is alike. Depending
on whether it is pure titanium or alloyed titanium,
the chip removing process behaviour differs. For these challenges
Mikron Tool has developed drills perfectly tailored to
the respective titanium grades, which can machine titanium
safely, with higher cutting performance results, longer tool
lives and excellent hole quality.
Titanium is highly demanding
Machining the unruly titanium is highly demanding. One
of the reasons is the combination of its properties of high
elasticity and tensile strength. Because of the high toughness,
chip breaking is difficult to achive. Due to its low thermal
conductivity, heat is not dissipated from the cutting area
through the chip. In addition, titanium tends to form builtup
edges. This all leads to higher wear and reduces process
reliability during drilling.
When drilling the challenge is even greater
And drilling is even more titanium challenging than milling.
The viscoelastic property of titanium causes the drill to stick,
and the pressure on the cutting edges increases. This usually
leads to uncontrolled drill breakage. Material sticking on
cutting edges and guide chamfers increase cutting forces, resulting
in cutting edges that can break out. Moreover also the
chip shape is problematic. This is because the titanium chips
tend to compact in the head area and prevent further chips
from flowing in. The high temperature load on the cutting
edges is an additional complicating factor.
Cool the tool!
To reduce the heat in the cutting area, the cooling lubricant
must reach the machining area directly. The two cooling
channels with very large cross-sections carry massive
amounts of coolant to the drill tip and guarantee constant
cooling, including lubrication of the cutting edges. At the
same time the massive coolant jet flushes the chips through
the polished flutes and prevents chip jams.
Innovative cooling concept
The patented special shape of Mikron Tool’s cooling channels
enables a four times higher volume of coolant to be shot
through the tool at the same pressure. This is a further key to
success and stands for innovation in the thermal dissipation
and chip removal technology.
Not all titanium is alike
To process this material efficiently, it is necessary to know it
down to the smallest detail. Mikron Tool has examined various
test materials and discovered that the diverse grades of
titanium are extremely different from each other, which is
of utmost relevance for their industrial machining. Pure
titanium (grades 1 - 4) is characterized by high corrosion resistance,
but has lower mechanical strength. Alloyed titanium
(grade 5 and higher) has high strength but low ductility.
Getting to grips with these differences in terms of machining
technology is a master stroke. Thanks to the meticulous
development work and the knowledge gained from it, the Mikron
Tool engineers found the perfect solution: two specific
geometries, one for pure titanium grades and one for titanium
alloys. In this way perfectly controlled chip removal,
high drilling speeds, long tool lives and repeatable processes
with optimum drilling quality are guaranteed for these difficult
titanium materials.
The new CrazyDrill Cool Titanium – twice as fast
The new CrazyDrill Cool Titanium series is offered in the
diameter range of .039" – 1/4" (1 – 6.35 mm). For pure titanium
Mikron Tool developed short drills with 3 x d and drills with
6 x d. For titanium alloys Mikron Tool relies on drills with
6 x d and 10 x d in combination with a pilot drill.
Product overview
For the cost-effective production of titanium components,
tools are required which are specially adapted to the material
properties of the various titanium grades.
Because titanium material as well as the workpiece are expensive,
it is of great importance to have high process reliability
and calculable tool live. If the latter can be improved, so
much the better. Mikron Tool’s new high-performance drills
for titanium have up to three times longer tool life and work
with twice the feed than current competitors. Another outstanding
aspect: drilling with the ATC-version is completed
in one shot, without multiple machining steps.
further information: www.mikrontool.com
no. 4, November 2023
21

news & facts
CERATIZIT acquires Xceliron corp.
Expert in solid carbide special tools for the aerospace industry
CERATIZIT S.A., part of the Plansee Group, has acquired
all shares of Xceliron corp. The Chatsworth, CA
based round tool manufacturer is focused on providing
special solid carbide tools for the aerospace and
automotive industries in the U.S.
“With its high-quality speciality products, the Xceliron portfolio
is an ideal complement to the standard products from
our Sacramento site and an important building block for our
global growth strategy,” says Mirko Merlo, president Americas
at CERATIZIT. Xceliron’s strong foothold in the aerospace
industry not only provides CERATIZIT with a launch pad
to tap into new customer groups, the company’s expertise in
the field of special tools also opens new opportunities to offer
CERATIZIT customers in North America an even more
comprehensive range of tooling solutions in the future.
Management stays on board
The forthcoming integration process will be actively supported
by the company’s founders. “We are very pleased
that Randy Jones and Ric DiOrio will continue the successful
management of Xceliron and act as co-managing directors,”
commented CERATIZIT executive board spokesman
Andreas Lackner on the closing of the transaction.
“We are thrilled to have found the right partner in
CERATIZIT to take Xceliron to the next level and build on
our heritage. Long-term thinking and creativity are two of
About Xceliron corp.
Xceliron corp. (est. 1990) is since more than 33 years a
precision cutting tool manufacturer and solution provider,
excelling in providing innovative solutions for difficult to
machine parts in the aerospace industry as well as
commercial and automotive sectors. From off-the-shelf
to speedy specials to application engineered solutions.
Mirko Merlo, CERATIZIT executive board member Melissa
Albeck, Randy Jones, Ric DiOrio and Andreas Lackner (l. to r.)
the values that have also been at the core of our business over
the past 33 years,” Ric DiOrio and Randy Jones say.
Specialization in the aerospace industry
Xceliron’s reputation for excellence in the aerospace sector
where upmost precision and reliability is required, perfectly
complements CERATIZIT’s commitment to quality and innovation.
This strategic synergy positions CERATIZIT to be
an industry leader in providing aerospace-grade tooling solutions.
Mr. Merlo adds, “This acquisition strategically positions
us to better serve our customers with an expanded range of
custom tooling solutions, specifically tailored to meet the demanding
requirements of the aerospace industry. We are eager
to leverage Xceliron’s expertise and reputation for precision
to drive innovation and excellence in round tools.”
further information: www.ceratizit.com
Tyrolit strengthens its US-market position
End of September 2023 the Tyrolit Group, a global
leader in abrasive solutions, has acquired all of the
stock of Acme Holding Company. Acme Abrasives is a
specialized abrasives manufacturer and provider based
in Michigan and is now Tyrolit’s seventh manufacturing
plant in the US.
This acquisition will further expand the product portfolio
for the steel and foundry as well as the rail industry. Acme
Abrasives is one of the leading manufacturers in North
America for hot pressed grinding wheels for the steel and
specialty steel industry’s grinding needs. Tyrolit will integrate
Acme wheels in its portfolio of grinding and specialty
abrasive solutions for industrial clients.
CEO Thomas Friess: “We have built a successful global economic
base that allows us to further pursue our strategic direction
of business activities. The further expansion of our
portfolio – especially for crucial industries like steel, foundry
and rail – strengthens our operational competitiveness.”
Commitment to high-quality
“With the addition of Acme Abrasives we will optimize our
customers’ benefit and utilize our global position. Acme perfectly
aligns with our values. We are excited about the opportunity
to offer high-quality products and services for a wide
variety of specific needs”, explains Matthias Kuprian, executive
board member Metal Industries.
further information: www.tyrolit.com
22 no.4, November 2023

news & facts
FANUC ships its one millionth robot
FANUC Corporation recently celebrated a significant milestone in
the automation industry by producing its one-millionth industrial
robot. The company which supplies customers worldwide with its
CNC-systems, robots and machine tools, is a pioneer in factory
automation and deployed its first robot in its own production line
back in 1974.
Today thousands of robots build new robots
in the company’s factories in Japan. “Demand
for our robots is currently at an all-time high”,
says Marco Ghirardello, the president and
CEO of FANUC Europe.
While industrial robots were traditionally
used mainly in the automotive and electronics
industries they have now become prevalent in
many other industries and businesses, including
food and pharmaceuticals and even in the
skilled trades. The worsening labor shortage
and the improved user friendliness are some
of the reasons for the spread of robotics into
new segments.
FANUC offers over 200 robot models that
perform various tasks in manufacturing, such
as welding, painting, assembly and packaging.
Collaborative robots (cobots) are gaining popularity
as they can work directly next to or together
with employees without external safety
fences. But traditional production robots still
dominate in the industry, and their use, such
as in the automotive industry, accelerates the
shift towards electromobility.
further information: www.fanuc.eu
SMART MANUFACTURING SUMMIT
Japanese and European innovation for Industry 5.0
GL events and Aichi prefecture, the industrial capital of Japan, have
teamed up to create the SMART MANUFACTURING SUMMIT by Global
Industrie.
This new trade event devoted to Industry 5.0 will include a high-level conference
programme involving speakers from the worlds of research and industry,
as well as representatives from European and Japanese government
bodies, all of whom will play key roles in defining the industrial landscape of
the future.
Moving towards the future
A series of high-level conferences, including tangible case studies, will take
place over the course of three days. They will address a variety of subjects,
including market expectations, the latest trends in Europe and Asia, partnerships
and cooperation, international agreements and public-sector programmes
to support business development.
The first day of the programme will focus on the objectives supported by
both Europe and Japan, while the second day will give an insight into the
different approaches to Smart Manufacturing in Europe and Japan. Presentations
and round-tables will give participants the opportunity to discuss
and learn more about various strategic issues and potential areas of cooperation.
The third day will be devoted to a more technical approach, with presentations
about Industry 5.0 aimed at building
a smart, sustainable future.
Speakers from both continents
Representing the private, public and academic
sectors, all the speakers are experts and decision-makers
willing to share their views about
the industry of the future and industrial cooperation
between Japan and Europe, the issues
and challenges of tomorrow’s industry.
During these three days of conferences,
and during the SMART MANUFACTUR-
ING SUMMIT by Global Industrie in March,
13 – 15, 2024, all the European and Japanese
players involved in “Industry 5.0” are invited
to come together at Aichi Sky Expo, the international
exhibition center of Aichi prefecture,
to discuss and find answers to questions concerning
industrial development, innovation
and cooperation.
further information: www.sms-gi.com
no.4, November 2023
23

news & facts
A quantum leap in efficiency and sustainability
MAPAL invests in India and expands its capacities. In
Coimbatore, the headquarters of MAPAL India, the
company recently opened a “Green field facility”. The
new company premises set standards in the areas of
production, technology and sustainability.
Since 2015 the headquarters of MAPAL India are in
Coimbatore, a city with over a million inhabitants in the
south of India. “Many of our nationwide customers and business
partners produce here and rely on our products and support”,
emphasises Thanigaraj Sripathy, CEO of MAPAL India.
Business in India and export business is developing well for
MAPAL India. Long-term growth is predicted for the Indo-Pacific
economic region, with positive effects for the machining
industry. “With an eye on the future, we have significantly
expanded the capacities in Coimbatore and invested
in a new company area”, says Dr. Jochen Kress, president of
the MAPAL Group. A production hall, a reception building
and an administration building have been built on an area
of about 8,300 m 2 ; production capacities have now tripled.
Additional space the size of four football fields is available to
ensure an expansion of the site in the coming years. “With
this investment we are strengthening our position as a leading
manufacturer in the upmarket tool segment and significantly
expand our capabilities in India,” Kress emphasises.
Faster, more accurate and more flexible
MAPAL India is successful in many business areas and supports
a loyal customer base, particularly in the automotive,
aerospace, wind power and mining sectors. 160 employees
at five locations coordinate all activities for the domestic
and export market. Special and standard tools are manufactured
at the headquarters in Coimbatore. The focus is on
PCD, fixed and fine boring tools as well as repairs and reconditioning.
Production is done in accordance with the MAPAL
Group’s uniform global quality standards. The ultra-modern
equipment of the new production plant enables even more
precise, safer and more flexible manufacturing processes.
And this with significantly shorter reaction times. “We will
also expand the product portfolio beyond the existing product
range,” announces Kress.
Sustainable production
The greenfield construction was designed and executed with
three clear objectives: zero maintenance (trouble-free production),
zero discharge (wastewater recycling) and green
compliance (environmental sustainability). An intelligent
building control system guarantees optimal manufacturing
conditions and ensures a consistent energy supply. The subsidiary
produces about one third of the required electricity
via photovoltaic systems on company-owned buildings and
parking areas. As a further contribution to environmental
and climate protection, investments were made in highperformance
HVAC systems (heating, ventilation, air conditioning),
resource-saving building materials, energy-efficient
lighting and sustainable landscaping measures. The company
premises are surrounded by a green belt with 1,800 native
trees and plants. These ensure clean air and a dust-free environment.
MAPAL India treats the waste water produced in
the factory and uses it for landscape irrigation.
further information: www.mapal.com
Expanding presence in Canada
ANCA Inc, a leading manufacturer
of grinders used for the creation of
precision cutting tools and components,
is excited to announce the
addition of Brady Roarke to the
America’s based team. Brady will
be located near Toronto, Canada.
This strategic move signifies ANCA’s
commitment to further strengthening
Brady Roarke its operations in the Canadian market
and enhancing its ability to serve clients
across the region. Brady comes to ANCA with an impressive
background in grinding machines, bringing nine years of ex-
perience and a proven track record of success as an applications
engineer. Five of those years were spent milling, and
four were spent grinding.
As the newly appointed applications engineer & technical
sales expert, Brady will play a pivotal role in expanding ANCA’s
reach in the grinding industry in Canada, both with new opportunities,
and expanding relationships with its existing
client base in the region.
The addition of Brady is part of the companies larger strategic
plan to expand its footprint and enhance its offerings
in Canada. This move underscores ANCA’s commitment to
delivering top-tier solutions and services that meet the evolving
needs of its Canadian clients.
further information: www.anca.com
24 no.4, November 2023

CERATIZIT appoints new president of the
Regional Unit Asia Pacific
news & facts
CERATIZIT is pleased to announce the appointment of Mr. Andreas
Fritz as president of the CERATIZIT Regional Unit Asia Pacific.
In his new role Mr. Fritz will oversee all CERATIZIT production and sales
sites across Asia as well as leading sales of branded cutting tool products
throughout the region.
With over three decades of experience in leading positions in the cutting
tool industry, Mr. Fritz brings a wealth of expertise to his new position.
“Today Asia is already an enormously important market for CERATIZIT
and still offers a great deal of growth potential moving forward,” said Mr.
Andreas Fritz. He will play a pivotal role in further strengthening the company’s
presence in Asia and capitalizing on the region’s immense growth
opportunities to further establish the brand as a market leader.
Beyond its strong position on the Indian market, CERATIZIT has a
very robust foothold in China and other Asian countries through the
CB-CERATIZIT joint venture, a fact that is especially true for the Hard
Material Solutions segment. The local know-how coupled with the sales and
production network CB-CERATIZIT form a solid foundation to further
drive growth in the region. As part of the company’s global effort to become
the sustainability leader in the hard metal and cutting tool industry,
Mr. Fritz will also lead the implementation of sustainable practices across
CERATIZIT’s operations in Asia.
further information: www.ceratizit.com
Andreas Fritz
Business network in Vietnam
Creation of “Italian Manufacturing Technologies”
The founding act of IMT-Italian Manufacturing Technologies, the
first business network in Vietnam among UCIMU member enterprises,
was signed on July, 20, 2024.
The network was signed by seven companies: Buffoli Transfer (Brescia), Ficep
(Gazzada Schianno, Varese), Gerardi (Lonate Pozzolo, Varese), Innse Berardi
(Brescia), Losma (Curno, Bergamo), Prima Industrie (Collegno, Turin),
Rettificatrici Ghiringhelli (Luino, Varese).
The initiative was created with the aim of supporting the network companies
in their activities of presence and penetration in one of the Asian
markets with the highest development potential, also because it is considered
the gateway to the ASEAN area. The initiatives by the network will be based
in Ho Chi Minh City and with the collaboration of local experts will materialize
into promotional activities to support the participation of the network
companies in sector exhibitions, as well as into the organization of visits to
potential user companies, of seminars and networking meetings among the
seven Italian enterprises and local operators, not only from Vietnam.
Barbara Colombo, president of UCIMU-SISTEMI PER PRODURRE asserted:
“I am very satisfied with the creation of IMT, which comes after two
years of intense work and a careful analysis of the market situation, conducted
also through the issue of a monograph dedicated to the country, in
addition to a study tour in the main areas of Vietnam”.
IMT is an operational means for the internationalization of companies interested
in working in the South-East Asian region. Based on the processing
of CECIMO and Gardner data by the UCIMU
Economic Studies Department & Business
Culture Center, in 2022, the ASEAN countries
saw their machine tool consumption grow by
about 20 %, thus extending the positive trend
registered from 2021.
With specific reference to Vietnam, consumption–
up by 34 % in 2022 – should remain
almost stationary in 2023 (+ 2 %). According
to the forecasts elaborated by UCIMU on the
basis of Oxford data, the demand for machine
tools should then grow considerably in 2024
(+ 13 %), in 2025 (+ 12 %) and in 2026 (+ 11 %).
The IMT initiative represents the second
network of UCIMU member companies. This
is added to ITC India, a network that operates
since 2012. ITC India was created with the
support of UCIMU for its member enterprises
and then also opened to the participation of
the member companies of AMAPLAST and
ACIMGA, which participate in the initiative,
even if they do not currently have any representation
of enterprises in the network.
further information: www.ucimu.it
no.4, November 2023
25

processes
Radically faster tool manufacturing
Things are happening in Trossingen, but hello.
After the promising presentation of the Multigrind®
Radical at GrindingHub in Stuttgart last May, the
high-tech tinkerers from the Black Forest are doing
even better. The gamechanger for all tool manufacturers
now also presents an ultra-compact, super-fast
automation system.
So we ask. How has the market reacted on the new tool grinding
machine? Is there any initial customer feedback? What
can automation do and why do people in Trossingen talk
about the best tool grinding machine in the world?
Our conversation partner Thomas Bader, technology
pioneer and managing director of Adelbert Haas GmbH, is
visibly proud of the new compact tool grinding machine.
Mr. Bader, the Multigrind® Radical set out to make
tool grinding faster, easier and more flexible,
as well as more economical and precise. Have you
been able to deliver on this promise? And what
do the first users tell you about this lucky bag?
Thomas Bader: Faster, more precise, more flexible, more
economical etc. That’s not what we were looking for when
we designed the Multigrind® Radical. With a new tool
grinding machine from Trossingen, better performance
values are a matter, of course, and therefore predictable.
We wanted nothing less than to revolutionize, transform
and thus lead tool manufacturing into the future. Hence the
name Multigrind® Radical and the nickname ‘Gamechanger’.
With the perfect choreography of software and hardware,
we succeeded perfectly.
Thomas Bader
The first Multigrind® Radical machines are now
at customers’ sites. What do they say about the
gamechanger?
Thomas Bader: The best compliment so far came from a
customer from the Swabian Alb. He said: ‘Now I not only
have a Porsche in front of my door, but also one in the
production hall. And the difference? The Multigrind® Radical
has more endurance and makes money.’ As an engineer
I am particularly happy about the Porsche compliment. Of
course also under the aspect of ‘grinding more beautifully’.
All joking aside: we have received positive feedback across
the board. Only the wish for fast and really uncomplicated
automation was still unfulfilled. Now we have added this.
How do you integrate powerful automation into
such a compact machine?
Thomas Bader: That was the challenge. An outstanding
feature of the Multigrind® Radical is its extremely compact
design. With a minimum footprint of around 2.7 m 2 and
a height of just over 2 m, it is ideal for the smallest of hall
environments. With integrated automation the footprint
increases to just 3.7 m 2 .
In return, the customer gets a fully automated and
super-fast production unit with built-in productivity
enhancements that set new standards in manufacturing.
Regardless of whether they are grinding straight rotary
or plate molds. And the new fast is also incredibly easy to
handle. (Thomas Bader laughs) Remember, a Radical doesn’t
take breaks, it just gives the tool time to recover.
Why don’t you tell us some specific performance data?
Thomas Bader: Well here are a few superlatives. We
drastically reduce non-productive time. Due to the parallel
26 no.4, November 2023

processes
tool and grinding wheel change, we save an enormous
amount of time and manage this discipline in just a few
seconds. Milling cutters, plates and drills are ground as
required. In large quantities or as a very small series from
batch size 1 to 1,000. Previously unrecognized potential
is raised here.
Assume that you produce 2,000 h per year in a single-shift
operation. Then, with an average machining time of 4 min
per cutter, you will produce 30,000 cutters per year in singleshift
operation. If you manufacture in two shifts, you will
produce 60,000 cutters, and in three shifts 90,000 cutters.
The industry average for a tool grinding machine is 30 s
for workpiece change and 15 s for tool change. A Multigrind®
Radical, on the other hand, requires 8 s for the workpiece
change and 3 s for the tool change. If we now assume that
the workpiece has to be changed once and the tool twice to
produce a milling cutter, the Multigrind® Radical saves 46 s
in non-productive time. This results in a savings potential
of around 77 % compared to the industry average. At an
hourly rate of 80 €, the Multigrind® Radical saves -.50 € per
workpiece change and -.26 € per tool change. That pays for
itself immediately.
In addition the machine can be quickly integrated into
production. This can be completed within a few hours,
i.e. without any loss of time and without any major
programming effort. Parameterization, templates and ERP
information are provided immediately by Multigrind®
Horizon software. This means that no control is required
and the gamechanger is immediatly ready for production.
All that’s left to do is quickly feed in the parts via automation
and off we go. This is definitely rock around the clock.
Rock around the clock, you’re referring to
unmanned production, right?
Thomas Bader: With the Multigrind® Radical, we want
to push the boundaries. A tool grinding machine without
limits. Thanks to its compact appearance, it is also perfect
as a solo performer for a garage start-up. The real purpose of
the Multigrind® Radical is to combine several tool grinding
machines into a hyper-profitable production cluster. Imagine
5 or 10 Multigrind® Radical side by side, there’s a lot going
on. This makes flexible, fully automated, unmanned series
production the production standard.
Freedom and maximum control
And why do people in Trossingen talk about the
best tool grinding machine in the world?
Thomas Bader: Exactly that was our claim. We set out to
design and then build the best tool grinding machine in the
world with the Multigrind® Radical. Operated by powerful
software that regulates everything in the background and
only serves to control everything in the foreground.
When, as in this case, aspiration and reality correspond,
it’s fair to call a spade a spade, isn’t it? And anyone who
Radical 830XW
knows Adelbert Haas knows that we only develop something
new if we can fundamentally improve what already exists,
otherwise we leave it. The time was ripe and we delivered.
Ultimately of course, it’s our customers who decide. Only
when they talk about the best tool grinding machine are we
satisfied and continue to tinker with the next big thing.
What prompted Adelbert Haas to develop just now a tool
grinding machine? The other Multigrind® machines are,
as the brand name suggests, rather high-tech grinding
machines with multiple applications. From medical
technology and aerospace to pumps and materials
handling.
Thomas Bader: It’s like always at Adelbert Haas, our
customers challenge us and we then try to exceed their
expectations.
And when it comes to tool grinding, this meets a very, very
long tradition in our company. As early as 1938, the HS 1
tool grinding machine was presented at the industrial trade
fair in Leipzig and repeatedly improved in the following
centuries.
In 1984 we then developed the first CNC 2-axis tool
grinding machine and replaced it in 1989 with the 5-axis
type HB 3045-5. The successful Multigrind® HT was born
in 1998. Many of these fossils are still doing a good job
and some are being brought up to date through our retrofit
program. Of course these retrofit machines do not make a
fair comparison with the new Multigrind® Radical; they are
worlds apart.
Anyone who has to face the competitive pressure of
automated production today definitely cannot do without
a Multigrind® Radical. That’s why, when it comes to tool
grinding, we have gone back to our roots, taken our
customers’ wishes seriously and followed our premise.
Who, if not us? When, if not now, and where, if not
here in Trossingen?
further information: www.multigrind.com
no.4, November 2023
27

processes
Big parts with equally big challenges
Giga castings in CNC machining
It has revolutionized automotive production: in
giga casting large structural automotive components
are produced in one piece, using high pressure die casting.
The process is a challenge – not only for die casters.
The following article sheds light on why the machining
of giga components is a difficult undertaking and how
solutions coul look like.
Following Tesla’s success, companies like Volvo are following
suit: in giga or mega casting, structural components such
as the underbody of a car are no longer welded, glued or
screwed together from many individual parts, but cast in one
piece. The process drastically reduces the number of components
produced and eliminates most joining operations. This
results in savings throughout the production chain. In addition,
giga components reduce the weight of a vehicle, which is
particularly advantageous in the field of electromobility: less
weight means greater energy efficiency and therefore a longer
range for the vehicles.
However, these advantages are accompanied by complex requirements
in production. Many of them come from the die
casting itself, from the huge casting molds and their temperature
control to subsequent cooling and the associated component
distortion. Even after the die casting has been successfully
completed, giga components remain challenging,
as product manager Michael Kreuzberger from SW points
out: “Discussions about giga casting have mainly focused on
the die casting process itself up to now. However, the complexities
of giga components go further. Machining these
large castings also presents several challenges that need to be
considered.”
Large machines, high space requirements
Some companies have already developed special large machines
for die casting, such as Tesla’s Giga Press. Reality
is much different when it comes to CNC finishing. It is
often still done on portal milling machines from the largeparts
manufacturing industry. “The components from giga
castings are simply much too large for conventional CNC
machining centers. The parts don’t fit in the machines”,
says Kreuzberger. “On the other hand, the systems from
large- parts manufacturing are actually too large and too
sluggish. Efficient machining is hardly possible on these single-spindle
portal milling machines. Machining times are too
long and loading and unloading is too time-consuming.”
So, on the one hand, companies face enormous space problems.
After all the die casting machines required for giga
casting alone can reach the size of a house. Add huge portal
milling machines to that and many production halls quickly
reach their limits. And only few companies have the same option
as Tesla, namely building a new, greenfield production
hall of the necessary size.
Cycle times do not meet automotive requirements
Even if sufficient space is available for large portal milling
machines, their long machining times are problematic in the
fast-cycle automotive industry. One reason for this is the use
of ball screws to translate rotary motions. Kreuzberger explains:
“In aluminum machining the non-productive times
are significantly higher than the pure machining times. The
larger the workpieces are, the longer the distances the feed
axes have to cover, for example during a tool change. Since
ball screws have lower accelerations and speeds, the non-productive
times get even longer.” In short, machines from the
large-part production sector generally cannot deliver the
cycle rates required in the demanding automotive industry.
Herein lies a major challenge in machining giga parts: achieving
typical speeds for the automotive industry on workpieces
this large.
Another challenge lies in the sensitivity of the components.
Since die casting creates stresses in the workpiece, large-volume
castings are susceptible to warpage. In electric cars in
particular, the wall thicknesses of the components have to be
Structural part – top
Underbody
28 no. 4, November 2023

processes
E-car
as thin as possible in order to save weight. This adds to the
warping risk. “The precision of the machine is not the problem.
Both large portal milling machines and smaller machining
centers can easily achieve the required accuracies”, clarifies
Kreuzberger. “Rather, it is a question of optimally matching
the workpiece to the clamping device in the machining
center and the gripper technology to avoid distortion during
machining.”
Higher speed thanks to linear motor
A solution for the sensitivity of giga components during machining:
“The clamping device must be developed specifically
for the respective component to fit exactly. Close cooperation
with the machine manufacturer is crucial for the best
individualized result”, says Kreuzberger. “At SW we have our
own department that is exclusively concerned with ensuring
optimum coordination between the clamping device and the
workpiece in close consultation with our customers.”
Things get more complex when it comes to the challenge
of required cycle rates. Here suitable machines with high dynamics
and the necessary space for the giga components are
required. In any case, users should opt for systems with linear
motors. The direct drive of a linear motor generates the desired
movements without mechanical transmission elements.
As a result it achieves maximum accelerations and the highest
traversing speeds, while also operating wear-free. “The
fastest CNC machines on the market all use linear and torque
motors, including most of our own machines”, Kreuzberger
says. “We also rely on a weight-optimized design. This allows
us to minimize non-productive and cycle times. Our
machining centers achieve acceleration values of over 2 g and
rapid traverse speeds of 120 m/min.” To harness this speed for
larger workpieces, SW launched the BA space3 in 2021. The
machine combines high cycle speeds with the space needed
for large castings. Only multi-spindle machines are faster.
New SW machine focuses on
multi-spindle capability
Currently there are hardly any multi-spindle machines for
large castings on the market. But SW is already working on
a machine that will introduce two spindles into its ‘space’
series. “In contrast to our other multi-spindle machines, the
two spindles will operate completely independently of each
other”, says Kreuzberger. “We are using two autonomous
three-axis units to allow maximum flexibility with different
components.” For medium-size components both spindles
can each work parallel on one component as usual. For larger
components where only one workpiece fits in the machine,
both spindles can work simultaneously on the same piece and
change tools independently of each other. A double swivel
carrier allows for parallel loading and machining, and ensures
a further reduction in cycle time. So giga parts like the
rear underbody of a Tesla can be machined in just 1.5 min
– almost twice as fast as with single-spindle machines.
“With the rapid development of electromobility, giga-casting
will continue to gain in importance over the next few
years”, concludes Kreuzberger. “Other automotive manufacturers
are also currently examining the advantages and disadvantages
of using large castings. Asian original equipment
manufacturers (OEMs) in particular are already relying
heavily on giga castings and are successfully installing them.
We want to do our part to ensure that the advantages of this
process outweigh the disadvantages and that the machining
challenges can be easily overcome as well.”
further information: www.sw-machines.com
no. 4, November 2023
29

processes
Functionally integrated implants through
novel synchronized machining processes – ZykloMed
With the joint project funded by the Federal Ministry
of Education and Research (BMBF), the participating
partners INDEX, Paul Horn GmbH, Beutter
Präzisions-Komponenten GmbH and the wbk Institute
for Production Engineering at the Karlsruhe Institute of
Technology (KIT) are demonstrating their expertise in
the medical industry.
Using new and modern manufacturing processes, the partners
have tackled the challenges for economical machining
of implants with multifunctional as well as non-round bionic
designs. The focus was on the three manufacturing processes
of eccentric turning, polygon turning and turn whirl milling.
Modern medical implants for orthopedics, traumatology
and dental technology are characterized by rigorous demands
on strength, biocompatibility and bionic-optimized geometry.
The geometry of an implant is adapted to the bone and tissue.
In the process, the functional surfaces of the implants
are given an increasingly sophisticated design in order to facilitate
their attachment in the body and make them less invasive
for the patient. The new designs of implants drive up
manufacturing costs because the surfaces are no longer circular
or square. They have more curved surfaces and functional
elements with continuous transitions in a very small
space. In particular the need for several manufacturing steps
on different machines causes costs to rise significantly. For
example, precise handling for exact re-clamping of a workpiece
represents a considerable cost factor. Therefore, despite
the high level of functional integration, an efficient process
route is needed for economical production.
Novel processes
The novel manufacturing processes of eccentric turning,
polygon turning and turn whirl milling are all based on the
same kinematic principle of multiple synchronized rotating
axes. While this principle is well known, its application to
non-circular and curved shapes is highly demanding. At the
same time, the practical implementation must meet the high
quality requirements of the medical industry.
The project partners researched and developed new manu -
facturing procedures along the entire process and supply
chain, from the machines and control technology to the tool
design to prototype and pre-series production. The manufacturing
processes were simulated and designed on known
methods with the same mathematical principles in order to
determine the requirements for tool and machine. The tests
were divided into equivalence tests under laboratory conditions
as well as pre-series tests and near-application environments.
The engineers focused on both machine and tool
technology for the development and design of the individual
processes.
In eccentric turning a rotating non-circular tool is guided
along a rotating workpiece under positional coupling. The
Polygon turning produces non-round contours on lathes
speeds are brought into a certain ratio to each other. The outof-round
shape is thus reproduced on the component within
certain limits, making the production of eccentric outer contours
possible. The rotation of the tool reduces the thermal
load at the cutting edge, which ensures long tool life. The process
also enables the production of tapered profiles.
Polygon turning is a process for producing non-circular
external and internal contours with the shape of a hypotrochoid.
Like rotary eccentric turning, the process offers the
possibility of producing non-circular contours on lathes. In
the process the parallel axes of the workpiece and the tool are
offset from each other by an axial distance and are brought
into a specific speed ratio under positional coupling. The axial
distance, the speed ratio of the workpiece to the tool and
the cutting diameter of the inserts define the dimension of
the contour. A tool system for polygon turning is individually
adapted to the contour of the workpiece to be produced.
Turn whirl milling is the process for producing threads for
bone screws. One or two circular milling cutters are set at a
certain angle to the workpiece. The directions of rotation of
the cutters and the workpiece can be the same or opposite.
The speed ratio of the workpiece to the two cutters depends
on the number of threads and the number of cutter inserts.
Turn whirl milling can also be used to produce economically
threads with a true variable pitch by dynamically changing
the thread profile.
Tests close to series production successful
With successful tests the partners of the ZykloMed pro ject
have made a big step to the goal of the research project, the
economic production of implants of multifunctional and
non-round bionic design. It was proven that the synchronized
manufacturing processes enable the economic production
of modern implants. Additionally to the production of new
component geometries, the processes also offer optimization
potential for the economic production of existing im plants,
as possible applications beyond the medical industry.
further information: www.horn-group.com
30 no. 4, November 2023

processes
Strong partners continue success story
with HiPIMS
The tool manufacturer Horn has been coating its cutting
tools with HiPIMS high-performance coatings in its own
coating center since 2015. From the very beginning the company
has relied on market-ready solutions from CemeCon.
Now Horn has received seven new CC800® HiPIMS systems
for its in-house coating center – including peripherals for
pre- and post-treatment of shank tools.
The quality of its cutting tools is the key to the market success
of Paul Horn GmbH. In 70 countries on six continents,
companies in the automotive industry, chemicals, aerospace,
medical technology or in tool and mold making use the precision
products of the Tübingen-based company.
The high-performance coatings of the tools play a major
role in the success. The company’s own coating center at the
site offers Horn maximum flexibility, also in the development
of new coating solutions. And what makes many of the tool
manufacturer’s customers particularly happy is that fast delivery
times are also possible for special tools and specific
small series. From the very beginning on the partner for the
operation of the systems has been the specialist CemeCon,
having developed the HiPIMS high-performance coatings to
market maturity and economic efficiency. “For the current
expansion and modernization of our coating lines there was
no doubt that we would once again rely on proven expertise,”
says managing director Markus Horn, appreciating the cooperation
with the technology and market leader.
Complete coating center from a single source
With seven new CC800® systems, Horn is sustainably expanding
its coating capacities in HiPIMS technology. Major
parts for the pre- and post-treatment of shank tools, such as
cleaning systems, blasting technology and quality control,
also come from the plant manufacturer CemeCon. Horn intends
to take full advantage of the “more” in autonomy and
performance gained with the support of its strong partner.
CemeCon will continue to supply all consumables and take
over maintenance services as well as individual user training
and support. Furthermore, in addition to the operational
business, the joint focus is on expanding the cooperation in
research and development as well as the combined strategic
development of new business fields for Horn’s cutting tools.
Markus Horn is firmly convinced: “It is key partnerships like
this with innovative strength that pave the way for us to remain
successful in a dynamic market.”
After all, CemeCon is also well aware of the challenges involved
in manufacturing precision tools. “A large proportion
of the tools manufactured at Horn are solutions that are
directly adapted to specific machining processes,” knows
Inka Harrand, the responsible product manager at CemeCon.
The right premium coating is just as important as the geometry
and the material of the tool itself: “Only the interaction
creates a solution that guarantees quality and enables productivity
and durability.”
Efficient in day-to-day business – highly flexible
in coating material development
The new CC800® HiPIMS systems with their open technology
are ideal for the changing requirements that characterize everyday
life at the Tübingen coating center. Clear user interfaces
and fast batch changes make work efficient even with
small batch sizes and complex mold shapes. Handling the
original CemeCon targets, which are an elementary building
block for the production of the coating materials, is also very
easy. As a result, the company produces completely smooth,
droplet-free and low residual stress coatings with maximum
adhesion and uniform coating thickness distribution of 1 to
8 µm for all tool sizes – technically possible even up to 12 µm.
New coating materials can be developed quickly, precisely
and economically from combinations of many elements of
the periodic table. Coatings can be finished directly on an industrial
scale. “In this way, we as a tool manufacturer have
the flexibility to react immediately to changing markets, new
customer requirements and – what is even more – to cover entirely
new fields of application,” says Dr.-Ing. Matthias Luik,
head of research and development at Horn, who is delighted
with the potential of the HiPIMS coating systems. “We are
thus securing important competitive advantages in the market
and creating tangible benefits for our customers.”
further information: www.cemecon.de
no. 4, November 2023
31

machining center
HELLER 360 ° solutions at EMO 2023
At the heart of HELLER’s presentation at EMO was
a 360 ° performance – a holistic view of the demands
placed on modern production. To meet these demands,
HELLER focuses on five solution areas. In addition
to the F 6000 5-axis machining center from the latest
generation of the F series, HELLER presented products
for the digitalization and automation of production, a
comprehensive range of services as well as innovative
manufacturing processes and technologies for complete
machining on a single machine.
HELLER’s commitment is to provide customers with machines
and systems that enable them to produce reliably and
at competitive per-piece costs in their day-to-day operations.
The company based in Nürtingen meets these requirements
with integrated manufacturing solutions that are suitable for
a wide range of industries. “We are successfully transferring
the high demands of the automotive industry to other exciting
sectors,” says CEO Dr. Thorsten Schmidt. This is also reflected
in the distribution of HELLER’s order intakes in the
first half of 2023 according to industries and workpieces.
Schmidt explains: “42 % of our order intakes come from
general mechanical engineering, power engineering, aerospace
and tool and mould making, among others. The truck
and agricultural sector accounts for 29 % of new orders,
while passenger cars still account for 3 %. Non-combustion
engine-related orders for heavy-duty and light-duty vehicles
accounted for 26 % of the total. Our aim is to expand into
even more industries – and EMO offered us a great opportunity
to do so.”
5-axis machining center F 6000 –
designed for production
The 5-axis machine with head kinematics is designed from
the ground up for flexible, powerful series production. Like
all of the companies machines it sets a benchmark for cutting
performance and precision. Highlights include 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 boasts first-class equipment, a small
footprint with a width of 3.70 m and expandability with technologies
such as Mill-Turn, interpolation turning or power
skiving. Dr. Manuel Gerst, head of the development group,
adds: “With the F 6000 we have succeeded in raising the
already high standard to a new level. This is also thanks to
newly developed key components ‘Made by HELLER’. These
include the completely redesigned swivel heads, including the
integrated motor spindles specially developed by the company.
The Speed Cutting Unit (SCU) in combination with the HSK-
A 100 tool shank reaches speeds of 15,000 rpm. As an alternative
HELLER offers the Dynamic Cutting Unit (DCU) designed
for universal use with 380 Nm and 12,000 rpm. For
heavy-duty machining, the Power Cutting Unit (PCU) with a
gear spindle and 1,150 Nm is still available.”
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
with speeds up to 700 rpm plays a key role. In line with the
trend towards complete machining this eliminates the need
for reclamping on separate turning machines. The result is
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
rotary pallet storage (RSP) and HELLER’s standardized linear
magazine solutions at a later date.
Another great strength of the F 6000 is its ease of use. The
comfortable main operating unit in console design with
32 no. 4, November 2023

machining center
24-inch touch screen, together with other features, ensures
that the operator quickly gets to grips with the machine. In
addition, the significantly wider door to the work area makes
it easier to access the workpiece. New processes can also be
set up quickly and safely on the machine with the optional
SETUP Assist. The new Siemens SINUMERIK ONE control
is available as standard. Existing NC programs from F and C
series machines with SINUMERIK 840D sl can directly and
easily be transferred by the user.
Automation solutions –
flexible, value-adding, competitive
On show at EMO was the RSP 12H6 rotary pallet storage.
With a total of 11 pallet storage locations as standard, the
automation solution enables flexible and automated handling
of machine pallets and is predestined for series production of
small and medium batch sizes. A third level can be added to
extend the solution to up to 17 storage locations plus loading
station. Augmented Reality was on the booth to demonstrate
its functionality and expandability.
The RZ50 robot cell from the companie’s automation portfolio
also provides an insight into flexible robot automation
for automatic loading and unloading of workpieces, fixtures
and pallets, as well as the automation of other handling tasks.
Also presented was the Automation Calculator. It allows
users to enter workpiece data, production information or the
desired machine into a touch-enabled terminal and then receive
recommendations on the most suitable automation solution
and the associated payback time.
Fit for the factory of the future –
digitalization
With a new intuitive operating concept, the HELLER Services
Interface ensures transparency in manufacturing, maintenance
and service processes throughout the entire lifecycle
of the machine. This option can also help reduce machine
downtime by providing evaluations and statistics.
Visualization of specific machine status information, including
status indicators for axes, spindles or other assemblies,
enables users to determine the wear status and take preventive
action to reduce unplanned downtime.
The digital twin provides customers with a digital image of
their machine. The simulation behaves exactly like the real
ma chine, and so saving much time and money during development,
commissioning and optimization. For example, the
use of tested workpiece programs prevents machine damage.
The HSU motor spindle with face contact check ensures
improved production quality in single-part and series production.
Contamination in the HSK tool interface is accurately
detected – chips as small as 10 µm can be detected both
in the taper and on the face contact.
Experience meets innovation – HELLER know-how
One key to higher productivity is complete machining on a
single machine. That is why the specialists are in the process
of integrating different technologies into the current range
of machining centers.
On the F 6000 5-axis machining center various turning
operations, power skiving gear cutting technology, trochoidal
milling, simultaneous 5-axis machining and an external
cylindrical grinding operation was presented as part of a
performance and technology demonstration in C45 steel.
Service – lifetime partnership
With the Full Service Essential, the Nürtingen-based machine
tool manufacturer offers its customers an attractive
package for complete cost control: for new machines, all
maintenance costs are included for a full three years, from
service calls to spare and wear parts, as well as annual manufacturer’s
maintenance.
The Blue retrofit solutions provide customers with energy
efficiency packages that effectively reduce operating costs
and minimize unit costs. The Blue Power Save, for example,
ensures that auxiliary units such as pneumatics, cooling
and lighting are switched off in stages as required. With the
Blue Coolant the energy consumption of the high-pressure
coolant pump can be reduced depending on the machining
process. The Blue Chill combines a powerful cooling unit
with a matching heat exchanger to equip machines for maximum
energy efficiency.
From now on customers in other European countries will
also be able to use the myHELLER customer portal to keep
track of their entire machine fleet all of the time. Spare and
wear parts can be ordered quickly and easily – from anywhere,
at any time. The portal for German customers was
launched only last year.
In addition, the companie’s experts are currently working
on web-based AI part identification for mobile devices.
HELLER Lens is designed to provide customers with even
faster and more reliable identification of spare parts
further information: www.heller.biz
no. 4, November 2023
33

machining center
Flexible machine concept successfully improved
Maximum process reliability, more flexibility
and excellent productivity: Liebherr-Verzahntechnik
GmbH has successfully overhauled its gear cutting machine
platform for workpieces with a 0 up to 500 mm.
The new machine generation now provides even more
flexibility. The highlight: easy chamfering during the
machining process is now possible using either ChamferCut
or FlexChamfer.
and FlexChamfer, which chamfers using common end mills
– perfect for small batch sizes. “This means that two chamfering
technologies have been integrated into one machine,”
says Breith, “something that is unique on the market.” An
automatic ringloader transports the workpiece from the main
machining position to the perpendicular chamfering position.
Internal gears can now even be chamfered on the gear
shaping and gear skiving machines.
An overview of the machines on the
redesigned platform: the spectrum of Liebherr gear technology
What is clear when looking at the modern, monolithic design
is that a lot has changed with this new generation. But
the technical improvements in this comprehensive overhaul
are even more remarkable. “In the past few years, we’ve continued
to improve the machine platform for machining workpieces
with a 0 up to 500 mm, optimizing the machine bed,
the chamfering device and the machining head”, explains
Thomas Breith, head of product management for Gear Cutting
Machines at Liebherr-Verzahntechnik GmbH.
Optimized for high performance
The machine bed was completely overhauled. For dry machining,
the machine table, machine column and box guideways
have been lined with stainless steel plates, ensuring improved
chip evacuation. This means that, in particular, the temperature
behavior remains constant, providing greater gear quality
and process stability. The reworked HH240 hob head on
the LC 500 gear hobbing machine with its longer travel ranges
and improved rigidity in its counter bearing guarantees high
performance. Optional add-ons include a swivel-in measuring
probe and a mobile meshing device for centering the tool
into the workpiece.
One of a kind: chamfering during the machining
process with ChamferCut or FlexChamfer
What is unique about the new generation is that an optional
chamfering device can be integrated into the machine, providing
two possibilities for chamfering during the machining
process: the fast and economical ChamferCut process
Longer travel ranges and optimized rigidity also provide
more stability and thus greater process reliability.
Greater user comfort thanks to
improved ergonomics
The user comfort and ergonomics of the machines have also
been optimized. A larger machining chamber, fold-out steps
and glass maintenance doors make it easier to access the machine,
and encased hydraulic units make it quieter. The control
panel with its LHGearTec user interface was improved.
The fixed LHStation monitor unit as well as the LHMobile
handheld terminal, both equipped with a Multi-Touch interface
and context-sensitive user guidance, make it even easier
to use and program the intuitive controls. Although the
monolithic design of the machines makes them seem larger,
their footprint is in fact smaller than that of previous units.
Modular system guarantees exceptional flexibility
For satisfying the requirements of a variety of sectors from
heavy industry to automobiles and other industrial applications,
Liebherr always relies on a modular machine concept.
Breith, “our gear cutting machines are robust, high-quality
and can be individually configured. Different table drives,
machining heads and automation solutions as well as optional
accessories satisfy a wide range of applications. We
were determined to continue this tradition in our new machine
generation.”
further information: www.liebherr.com
34 no.4, November 2023

machining center
New universal
loading system
STUDER S31
with insertLoad loading system
insertLoad at a glance
➤ efficient standard solution
➤ universal use
➤ operation through setup wizard
➤ loading between centers or in a chuck
➤ full integration in machine design
Where customized solutions were previously neces-
sary, the new universal loading system from STUDER
now enables standardized automation for loading and
unloading the S33 and S31.
insertLoad can be used for center distances of up to 1,00 mm
(39.4 inches), thus closing a gap in standardized automation
systems. The workpieces can be up to 100 mm (3.94 inches)
long and weigh 1.5 kg (3.3 lbs) in alternating mode or 5 kg
(11 lbs) in a single mode. The sophisticated design and the
ease of use with the digital setup wizard allow users to configure
this themselves for centers and chucks – no programming
knowledge is required. And insertLoad can handle
workpieces that are stored either vertically or horizontally.
The best combination of standardization
and flexibility
The new STUDER loader combines the advantages of a standardized
system with great flexibility. It handles a wide variety
of parts in terms of geometry, weight, and size; even the
capacity of the drawers and the degree of autonomy can be
adapted based on the needs and requirements. Loading and
unloading is handled by a Fanuc robot, which moves independently
on a linear axis between the loader and the
machine’s work area. Typically, the time without human
operator intervention is between thirty and sixty minutes.
Gripper for workpieces clamped in a chuck
STUDER placed particular emphasis on safety during development.
For example, a loading hatch separates the loading
area of the insertLoad from the working area of the
machine to prevent flame flashback during machining processes
using grinding oil. In addition, the software and a
safety switch ensure that grinding technicians are not endangered
in the event of a deflagration.
Availability for additional machines planned
The insertLoad was presented to the international trade public
for the first time at the world’s leading trade show for
metalworking, EMO. Initially, it will only be available for the
S33 and S31 CNC universal cylindrical grinding machines,
but the availability for other models is in preparation. The
S33 and S31 are ideal grinding solutions for small to large
workpieces in single, small batches and volume production.
Both machines feature distances between centers of 400 to
1,600 mm (15.75 to 63 inches) and a center height of 175 mm
(6.9 inches).
Gripper for shafts clamped between centers
further information: www.studer.com
no.4, November 2023
35

machining center
Connecting the art of engineering with
digital know-how
Automotive and supplier industry, rail transport,
aerospace – in these and many other industries, production
processes are changing rapidly and from scratch.
In the spotlight: digital technologies, robotics and artificial
intelligence – they are shaping industrial manufacturing
more and more and make sure that physical
and virtual processes are closely intertwined. Highquality
machine tools and processing centers in combination
with data competence and simulation expertise
are in demand.
3D simulations for more efficient production lines
At the FFG Group booth at EMO, visitors could experience
live at numerous exhibits how mechanical engineering
and digital know-how can be combined to create measurable
added value: maximum flexibility, low costs per part, and
optimal efficiency, as well as energy and resource savings
on the way to climate-neutral manufacturing. “To find the
most effective and economical arrangement of workstations,
machines and robots, we use 3D simulations. With these planning
tools, we can plan assembly and production lines both
efficiently and realistically”, says Dr. Sebastian Schoening,
CEO of FFG Europe & Americas. As a so-called process
twin, the three-dimensional representation delivers accurate
and reliable results and makes production processes
and customer- specific details transparent. A digital product
twin is also created on the basis of the 3D design data – it
visualizes the technical specifications as well as the design of
the individual machines.
A virtual immersion in production planning
The intelligent combination of these two information streams
leads to a digital plant twin: it represents the overall system,
which can be used to implement all planning, changes and
inputs for virtual testing before commissioning. FFG’s experts
literally immerse themselves into production and material
flow planning and can run through a variety of what-if
scenarios. This opens up deep insights into processes, minimizes
investment risks and saves costs. For new product
launches, connected and integrated production systems ensure
manufacturing excellence from day one.
Smart controls reduce CO2 emissions per part
The energy consumption of machines and systems can also
be calculated precisely for different production environments.
There are numerous starting points to reduce the energy
requirements of machine tools. “When it comes to implementing
energy-saving solutions, we see ourselves as frontrunners.
Above all intelligent software control helps to keep
the CO₂ footprint per produced part low and makes the
operation of entire manufacturing systems sustainable," says
Dr. Sebastian Schoening.
further information: www.ffg-ea.com
36 no. 4, November 2023

Automation and digitalization in
machine tool building
machining center
Doosan Machine Tools becomes DN Solutions.
DN Solutions participated for the first time under
a new name at the world’s largest machine tool trade
fair “EMO 2023”. The machine tool manufacturer presented
a selection of state-of-the-art machines.
DN Solutions presented 20 machines to the trade public at
close quarters. The exhibits were divided into three categories
and represented high-productivity automation, smart manufacturing,
and advanced 5-axis/composite processing. In the
“Flexible Automation” area visitors experienced the seamless
integration of various solutions for workpiece handling, including
robot, gantry loader and pallet system solutions.
This included the compact turning center (PUMA
DNT2100) equipped with a collaborative robot, the twospindle
horizontal turning center (PUMA TW2600M) integrated
with a gantry loader, the horizontal machining center
(NHP 5000) featuring a rotary pallet system and the compact
5-axis vertical machining center (DVF 4000) with the Automatic
Workpiece Changer (AWC).
In the “Real Digitalization” category, DN Solutions presented
intelligent manufacturing solutions based on userfriendly
technologies for digital transformation. The advantages
of digital twin technology was demonstrated, including
the minimization of error sources through virtual verification
and the reduction of machine set-up times. With the
multi-tasking PUMA SMX3100ST, DN Solutions also exhibited
skiving machining technology using the table turning
function. Additionally several live machining demonstrations
were conducted with the purpose of showcasing the
unique features and characteristics of each machine.
The topic of sustainability also played a major role.
Under the motto “Green Forward” DN Solutions presented
energy-saving systems such as the mist-free solution for oil
mist separation and the power consumption monitoring system
at the trade fair. The mist-free solution offers the particular
advantage of minimizing motor power. This leads to
lower electricity and maintenance costs.
International cooperations
underlined trade fair presence
Another highlight was shown at the Siemens stand. In cooperation
with the German player, the SMX2100ST multitasking
machine has been equipped with SINUMERIK ONE,
Siemens’ CNC system optimized for the digital twin.
further information: www.dn-solutions.com
no. 4, November 2023
37

machining center
Perform a variety of grinding tasks
in quick succession
Extreme dimensional accuracy, maximum
efficiency – under these specifications,
external cylindrical grinding is
an indispensable process for contract
grinders, medical technology, general me -
chanical engineering and many other industries.
However, especially for smaller
series or prototype production, it is important
to have a grinding solution that
is as universal as it is flexible, and that
canbe retooled and configured in a very
short time.
The graphical dialog
interface is based on
Windows and simplifies
massively the input of
technology parameters
for a given cycle
How can process reliability and accuracy
be guaranteed under these circumstances?
EMAG Weiss provides an answer to this question
with the W 11 CNC cylindrical grinding
machine for workpieces with a 0 of up to
500 mm and a length of up to 1,500 mm. The
entire technology is designed to perform a
wide range of machining requirements in
rapid changeover.
The initial situation is as familiar as it is
challenging: many users in industry machine
shafts and other rotationally symmetrical
components are using a final cylindrical
grinding process. Subsequently the surfaces
exhibit exceptional precision and quality in
the µ range. However, smaller quantities or
prototypes thus become a special task, because
each machine set-up takes a relatively
long time – and, of course every error must be
avoided. In this context the W 11 CNC from
EMAG Weiss is a special solution: a CNC-supported
external-internal cylindrical grinding
machine, which can also be operated manually
or be equipped flexibly with different grinding
wheels. For example when machining
with one wheel from the side, parallel one can
use machining with two external grinding
wheels or the combination of internal and external
grinding wheels (as well as many other
variants). Also there are few restrictions on
the type of wheels – 0 of 400 or 500 mm and
widths of 10 to 120 mm are possible.
Intuitive operation facilitates processes
The aforementioned flexibility is ensured by
a whole bundle of measures. For example the
basic control system already contains all common
grinding cycles. The operator calls them
up via an easy-to-understand dialog interface
Optionally the machine is equipped with automatic doors,
making the interior easier accessible
The external-internal cylindrical grinding machine can also
be operated manually
38 no. 4, November 2023

machining center
and enters the required dimensions via
fields. In addition automatic dressing, grinding
of several diameters, saving of grinding
sequences, contour dressing and taper grinding
in path mode are all easily possible with
the CNC control. But also the following always
applies here: anyone who wants to carry
out the process manually can do so at any
time, bypassing the CNC control. In any case,
the good accessibility of the machine facilitates
the operator’s work.
At the same time the mechatronic details
around the workhead, tailstock and grinding
head of the W 11 CNC score points when it
comes to executing fast changeover processes:
➤ for example, the spindle mount (with
MK4, MK5 or MK6 adapter) has a
precision bearing, and the speed can
be continuously adjusted from 1 to up
to 650 rpm – even 2,000 rpm is possible
as an option
➤ the tailstock (MK4) can be operated
manually and pneumatically by foot
switch; the quill holder with a stroke of
45 mm enables loading between centers
up to a weight of 250 kg; optionally the
machine can also be equipped with
an NC tailstock with a travel of up to
300 mm for a maximum workpiece
weight of 350 kg; in addition manual
cylinder correction is also another option
➤ also standard (and important for
flexibility) is a direct-drive B-torque
axis for stepless swiveling and positioning
of the grinding head with a resolution
of just 0.0001 mm
➤ last but not least, optional in-process
measurement based on Marposs
measurement control is available
Changeover processes
in just five minutes
The effect of this combination of high-tech
equipment and intuitive control is demonstrated
by various practical examples, as the
machine is currently in use in many facilities.
For example the experts at EMAG Weiss
estimate that many changeover processes
just take five minutes. This example shows its
value in the production of part families with
multiple component changes, leading to enormous
time savings over a shift or a week – and
always against the background of enormous
dimensional accuracy with tolerances of just
0.001 mm. Additionally users have a futureproof
solution that can handle a wide range
of tasks.
further information: www.emag.com
Flexibility is the key: the W 11 CNC can be operated
with a wide range of grinding wheel arrangements
Workpieces with a 0 of up to 500 mm and a length of up to 1,500 mm
can be finished in quick succession
The W 11 CNC cylindrical grinding machine is predestined for single-part and
prototype manufacture: it is also used for small series and sample production
no. 4, November 2023
39

machining center
ULTRA technology enables
high quality production of small and micro tools
ANCA, the grinding technology experts, presented
two new machines at EMO. The MicroX ULTRA sixaxes
machine is designed to meet the demands in a
micro tool volume production environment, the machine
has the nanometer control and optimized kinematics;
fast wheel change, tool setup and an uninterrupted
tool grinding to offer superior micro tool
grinding. Micro tools are an important and growing
industry, servicing 3C, medical, automotive, watchmaking
and jewellery industries.
Pat Boland, ANCA co-founder said: “The MicroX propels
ANCA products into an important market segment:
microtools. Leveraging ANCA’s cutting-edge ULTRA grinding
technology and MicroX kinematics, the intelligent technology
offers exceptional precision, unwavering stability, and
heightened productivity upon tools spanning a 0 spectrum
from 6 mm to a mere 0.05 mm.”
The ULTRA technology which is applied in the MicroX,
has been introduced by ANCA last year on their MX machine
series. ANCA’s vertical integration and 50 years of partnership
with cutting tool makers means that this machine combines
industry knowledge, market needs and ground breaking
technologies to offer the market advanced solutions. New
software, hardware and design features significantly improve
surface finish, accuracy and controlled runout, ensuring
batch consistency from the first ground tool to the last.
In addition to the MX, ANCA presented the renowned
universal FX series as an ULTRA version. “The FX7 ULTRA
introduces cutting-edge technologies that revolutionize precision
grinding for small tools down to 0 0.1 mm. If you produce
tools such as ballnose, corner radius endmills and complex
or intricate profile tools, then this machine is for you,”
says Darren Fox, ANCA product manager.
The FX7 ULTRA
is the go-to
solution for
precision
grinding in
industries that
rely on small
tools
FX7 ULTRA offers
unparalleled accuracy
for small tools down
to 0.1 mm
The ULTRA package
➢ one nanometer control system
➢ new servo control algorithm for smooth motion
➢ system and mechanical upgrades enhance
stiffness and rigidity
➢ in-process measuring, balancing and runout
compensation for consistent accuracy
➢ Motor Temperature Control (MTC) –
ANCA’s patented innovation
➢ specialist training support from our engineering
experts on how to grind perfect cutting tools
As a dedicated micro tool grinding machine, the MicroX
ULTRA brings along some further features, such as its optimized
linear axes travel with ballnose grinding wheel point.
The C-axis refers to the wheel swivel axis centerline, which is
aligned with the wheel’s 9 o’clock grind point. This specific
design is critical in the grinding of ballnose, corner radius and
profile tools. In the case of a ballnose tool, the X and Y interpolations
during the grinding process will be nearly equal
to the radius of the ballnose tool. Apart from the optimized
axes travel to grind tools to micrometer sizes, the developers
introduced a fast tool setup change including wheel change,
fast wheel change and access to up to 8 grinding wheels, and
uninterrupted continuous micro tool production.
In a volume production setting, micro tools are manufactured
using an uninterrupted continuous loading system.
This system allows for the removal of a pallet containing
ground tools and the seamless loading of a pallet with blanks
into the process, all without the need to halt the grinder.
With a 0 of D 3 mm and the use of three full pallets, the production
capacity amounts to 2,520 tools. However, the most
significant advantage of this added feature is that it unlocks
the potential for an unlimited production capacity.
further information: www.anca.com
40 no. 4, November 2023

Surface quality and removal rate doubled
Laser machining center Femto E3 becomes more powerful
machining center
In 2020 Kern launched the first ultra-short pulse
laser center Femto E3. With the latest developments –
especially in the case of process parameters – the
engineers from Kern achieved an essential increase in
productivity.
The manufacturing of carbide press punches, which are used
to produce inserts and other small parts, received an enormous
boost in terms of cost-effectiveness and productivity
with the Kern Femto E3 around three years ago. On the one
hand there are no tool costs when working with the femtosecond
laser. On the other hand time needed for manufacturing
is far less than time needed for erosion and milling.
With a lot of know-how and intense engineering Kern now
succeeded, after only three years, to optimize parameters like
pulse power, pulse time and scan speed so that the manufacturing
of carbide press punches becomes even more productive.
No matter for what application, the results are a significantly
improved surface quality and removal rate.
The single values could be doubled and were proved by
orders from customers and demo parts, as could be seen at
EMO 2023. Quirin Herterich, responsible for sales of laser
technologies at Kern provides the numbers: “Up to now we
achieved a removal rate of around one cubic millimeter per
minute with tungsten carbide press punches, now we are constantly
at two cubic millimeters per minute.” Equally interesting
are the improvements in surface quality achieved by
Kern – from the previous Ra = 0.2 µm to now Ra = 0.1 µm. This
means that the final polishing can be shortened significantly,
which has a correspondingly positive effect on the overall
running time of the parts.
The strong Kern: Quirin Herterich, responsible for sales of laser
technology; Stefan Kletzenbauer, laser processing developer and
Daniel Asam, laser processing development manager (l. to r.)
This small sample part
shows the high performance
of the Kern Femto E 3
Energy efficient, reliable and easy automation
Regarding cost-effectiveness, Kern’s ultra-short pulse laser
center scores in many ways, like no costs for tools. Additionally
lower energy consumption compared to other technologies,
because of the very economical laser source with an output
of 20 W. The simple operation contributes significantly to
process reliability and good automation. Ultimately the designer
does most of the work by creating the 3D CAD data. At
the end he converts this into a so-called negative model and
transfers it to the Kern Femto E3. The machine operator then
only has to activate the material-dependent parameters, enter
the number of parts required and start the program. The machine
does everything else – 100 % error-free.
When is it worth purchasing a Femto E3?
According to Quirin Herterich, there is no general answer
as to who can benefit from purchasing the innovative femto -
laser center, since many different parameters have to be taken
into account: “We always discuss options together with the
potential customer,” says Herterich, but still gives a thumbnail:
“As a rule, the purchase is worthwhile if the machine
is used for around 2,000 hours per year, which roughly corresponds
to continuous single-shift operation.” During this
time, depending on the topography, around 500 to 1,000
punches can be produced.
As an alternative to purchasing the Femto E3, Kern offers to
manufacture it to order. Meaning that even smaller quantities
up to batch size 1 can be produced economically. This applies
for example if prototype parts have to be produced in several
loops. Then all you have to do is adapt the CAD data and convert
it to the negative model. The new part can now be created.
“Minimal effort compared to other manufacturing processes,”
confirms Quirin Herterich.
The Kern laser technology expert is certain that the Femto
E3 will soon open up additional fields of application. “We
now use processing software that allows very fine texturing
to be introduced onto small parts.” This means that lines,
troughs, or free shapes with just 10 µm or 20 µm can be created
into any surface according to customer requirements.
There are many applications for this.
further information: www.kern-microtechnik.com
no. 4, November 2023
41

machining center
A brand of its very own
At EMO 2023 CHIRON Group interpreted the exhibition
motto “Innovate Manufacturing” in its own
way and presented its comprehensive portfolio for the
first time under the globally uniform CHIRON Group
brand. This included machine innovations live under
chip, a highly variable automation solution and innovative
services.
Machining highlights in live operation
In recent months the CHIRON Group has continued its
product offensive and presented five machining centers in
live operation. An absolute crowd-puller was the DZ 22 S mill
turn for flexible, piece-cost-optimized production of small to
medium batches, for example of e-motor housings. The next
generation of the 15 Series celebrated its premiere with new
rotary tables developed in-house and the intuitive Siemens
SINUMERIK ONE control. On show was the DZ 15 W with
180 ° swivel table, two separate workspaces and workpiece
changer for efficient milling of large batches. Customers from
the medical and precision technology sectors were able to experience
highly dynamic and autonomous micromachining
in the smallest of spaces on the intelligent combination of the
Micro5 machining center and the Feed5 handling system.
Also on the topic of automation, an innovation could be
seen live: the VariocellMove for intelligent workpiece handling;
the compact robotic cell with inclined pallet system
can be flexibly combined with milling and mill-turning centers
from the CHIRON Group to form a productive unit.
Innovative services
The experts from the CHIRON Group Service presented the
new customer portal myCHIRON with an e-shop for fast ordering
of spare parts and a new service: Repair, refurbishment
and optimization of motor spindles. An innovative offer
– already available in Germany, Austria and Switzerland –
makes it easy to get started in quality manufacturing:
PerformanceFinance, a complete machine financing package
including cyclical condition monitoring and comprehensive
services. Those who already have a machining center
from the CHIRON Group in operation were able to obtain
information about an individual refurbishment. Such
an “upgrade” makes an existing machining center fit for new
manufacturing tasks and not only saves financial resources,
but also protects the environment.
further information: www.chiron-group.com
Gear center for use in the prototype sector
up to large series production
The KNG 350 flex is based on a compact, stand-optimized
machine concept for use in the prototype area
to large-scale production of gears up to Ø 350 mm. An
optional diameter extension is available.
Available machining processes are generating and profile
grinding, depending on the application with dressable corundum
or non-dressable CBN tools. A unique selling point is
polishing as a single technology, for example to finish gears
after shot peening.
The performance-optimized grinding spindle with counter
bearings allows cutting speeds of up to 100 m/s and is
designed for the use of large grinding worms with widths of
up to 200 mm. This allows an efficient realization, especially
when machining of components with large modules and
using 2-sector worms for fine grinding or polishing applications.
Auxiliary spindles can be adapted directly on the tool
spindle using the new quick-change interface. Due to the use
of auxiliary spindles, very small grinding wheels with the
minimum root circle of the gear to be grind, can be applied.
The integrated reduction stage enables a cutting speed of up
to 50 m/s even with a grinding wheel 0 30 mm.
A reduction in set-up times is also achieved through the
use of intelligent components (smart tooling). From manual
loading, via a simple pallet conveyor, to a comprehensive
automation solution, the concept offers full flexibility in loading
the components. The functional and ergonomic machine
design paired with the innovative user-friendly interface KN
grind supports the user during set-up and optimization of
grinding projects.
Process monitoring, part tracing and inline quality assurance
are available as an integral component for an industry
4.0 capable processing machine. This gear center impresses
not only with its excellent design (iF Design AWARD), but
also with its continuous further development with a view to
energy efficiency. The hydraulic functions, which are reduced
to a minimum, are covered by a controlled pump unit, and
pneumatic functions are largely replaced by electric drives.
The consideration of the complete life cycle of the machine
shows, the entire CO 2
equivalent of the machine, is reduced
by changing the machine bed from cast iron to polymer
concrete.
further information: www.kapp-niles.com
42 no.4, November 2023

machining center
Reducing throughput times, eliminating operations
with no added value and optimizing processes
The LEAN philosophy has been deeply ingrained
within Rollomatic for numerous years, forming an integral
part of the corporate culture and permeating
the design of all products. Reducing throughput times,
eliminating operations with no added value and optimizing
processes are just some of the challenges facing
our customers. The GRINDSMART® 660XW, a new
model designed by Rollomatic, is a perfect illustration
of this. By combining it with the GRINDSMART®
830XW model, Rollomatic is able to offer grinding
solutions covering the entire diameter range of micro
and macro tools.
The solution for high-performance rotary tools
with 0 0.1 to 12.7 mm
Complete tool grinding solutions, including cylindrical
grinding in a single clamping operation. The ultra-compact
GRINDSMART® 660XW 6-axis high-precision grinding
center has been designed to produce rotary cutting tools with
0 ranging from 0.1 to 12.7 mm, and includes a high-capacity
tool loader and ultra-fast wheel changer. Its unique and
innovative design provides superior accuracy and reliability.
This machine has been designed for the production of large
or small series of high-performance cutting tools.
6-axis kinematics
The machine features 4 linear and 2 rotary axes. The unique
aspect is the workhead which is mounted on a CNC linear
axis. With this feature, the tool grinding and the well-known
Rollomatic peel grinding process are combined together into
a single machine model. The benefit of the traveling workhead
for peel grinding operations is that the grinding wheel
is always on top of the steady rest while the workhead axis
is pushing the tool through the grinding wheel, providing
excellent process stability. This CNC workhead axis is also
a great benefit for drill applications, as an innovative steady
rest design combines optimal tool support for fluting and for
pointing.
Advantages
• the Lean Grinding Process provides significant
reduction in cycle times
• integrated ultra-compact tool loader, 1360-part capacity
• 6-position high-speed wheel changer
• exceptionally short set-up times with the help
of the Smart Setup Assistant
• low energy consumption
The solution for high-performance rotary tools
up to 0 32 mm
The GRINDSMART®830XW is designed for both large and
small production runs and features six simultaneously interpolated
axes, with an innovative combination of hydrostatic
technology and linear motors. This feature, which is unique
GrindSmart 830XW
in the cutting tool industry, provides very high rigidity and
dampens vibrations that may occur during machining, increasing
the life of the wheels and guaranteeing unbeatable
surface finishes, giving users a real competitive edge. Autonomy
is another advantage, allowing unattended produc tion
over an extended period without human intervention.
Advantages
• maintains constant grinding point for relief operations
on ballnose, radii and form tools
• unlimited flexibility of movement due to the 6 th axis
design and the total symmetry of the spindle axis
• 10-pallet capacity, up to 4,500 blanks
• wheel pack changeover under 11 s
• mirror surface finishes
• razor sharp cutting edges
• geometric accuracy below 0.003 mm
• dimensional repeatability in production below 0.01 mm
Automatic measurement and compensation system
VIRTUALGRIND®PRO the innovative and powerful programming
software that comes with GrindSmart® CNC
grinding machines. This software platform is used across
the entire range of Rollomatic machines and provides the
user with the ability to program and grind various types of
cutting tools, whether they are standard or complex.
It is equipped with highly valuable features, including the
Smart 3D Simulator. This function replicates the programmed
tool in a 3D simulation and showcases machine animations
prior to the grinding process. This not only minimizes setup
time but also mitigates the risk of potential collisions. Further
built-in elements are the Smart Setup Assistant, designed
to achieve the first ground tool within specified tolerances,
and the In-Process Measurement feature, which conducts
laser or touch measurements to apply necessary compensations,
ensuring reliable and unattended production.
further information: www.rollomatic.ch
no. 4, November 2023
43

components
Aerotech brings movement to the
automation process
With around 50,000 trade visitors
and almost 1,000 exhibitors, the SPS
in Nuremberg is one of the world’s top
events for control and automation technology.
Aerotech will also be presenting
its high-precision motion control and
positioning solutions November, 14 – 16,
2023 (hall 3, booth 251).
At the exhibition stand components as well as
the motion control platform Automation1 will
be demonstrated as integrative components
in the automation process. Together with the
current Automation1 Release 2.5, the digital
PWM drives XA4 and iXA4 will be presented
to the visitors for the first time. In addition,
a gantry system with a rotating bridge will
be presented that exemplifies the possibilities
of coordinated movements and transformations
of Automation1.
“The motto of this year’s SPS, ‘Bringing
Automation to Life’, is something that I would
like to make a little more precise for Aerotech
‘Bringing Automation to Motion’”, says Simon
Smith, looking forward to the Nuremberg
trade fair. The European director at Aerotech
has good reason to do so, because his topics
fit perfectly into the trade fair concept, from
control components to automation.
Simon Smith: “For Aerotech I’d like to change this year’s SPS motto from
‘Bringing Automation to Life’ to ‘Bringing Automation to Motion’ ”
Simon Smith specifies: “As a manufacturer of automation systems we support
manufacturing companies in optimally automating their processes
with our precision motion components.” Aerotech has developed its motion
control technology into the Automation1 motion control platform. This
platform can control almost any peripheral device, from linear motion to
handling robots to measuring systems. Simon Smith emphasises the flexibility
of the motion control platform: “Users can use Automation1 to support
their automation process beyond pure motion control. If the process changes
and new peripheral components are added, they can be easily integrated into
Aerotech has been strengthening its commitment
to automation for years and is also
positioning itself as a system supplier for highquality
motion control and positioning systems
as well as complete automation solutions
for the SPS. For over 50 years the company has
offered a wide range of components, such as
motors, drives, controlers and positioning tables,
the majority of which are manu factured
in-house. These components are used in a
wide range of applications, from electronics
manufacturing to medical technology and
additive manufacturing.
But Aerotech goes a step further by developing
integrated systems that provide near-turnkey
solutions for automated processes. These
systems include not only the precision motion
control components manufactured in-house,
including the control platform, but also comprehensive
automation integration for part
handling, process instrumentation, safety and
custom software.
Camera module integrated into motion control: a camera recording is displayed
as a live video feed with optional crosshairs, the acquisition and display of
images and axis positions directly on the screen of the control platform
44 no. 4, November 2023

components
Block diagram of the decoupling control
Automation1 without having to purchase new control software.
We will be happy to demonstrate how this works to
trade visitors at the SPS.”
Automation1 with more and more functions
The latest version 2.5 of the Automation1 motion control
platform comes with a wealth of new features that significantly
improve research, development and industrial automation.
Simon Smith comments: “With these additional functions
and the user-friendly interface we are once again demonstrating
our expertise as a leading provider of precision
motion controls for the most diverse automation solutions.”
position of the logical linear axis (R) is thus simply the average
of the two physical actuator positions. The logical rotational
position (Theta) is the difference between the two actuator
positions divided by the distance between the two actuators.”
In an H-bridge gantry, the logical rotational axis results
in a yaw movement of the gantry. Decoupling control is also
referred to as yaw control. The position control loops act on
the logical linear axis (R) and the logical yaw axis (Theta) and
not on the physical axes. (see the block diagram)
Galvo scanner calibration is now easier. Users can change
calibration and power correction files for galvo laser scanners
without resetting the control. Support for higher derivative
feedforward control has been improved and laser scan head
drives now automatically interpolate feedrate.
Gantry and encoder functions also have been enhanced.
There is a new wizard for homing gantries and users can output
quadrature or clock and direction signals from a specific
encoder port. A checklist module makes Gantrys setup easier,
and Gantry configuration has been optimized.
Another interesting option is the integrated camera module
in the MachineApp from Automation1. Allowing users to
monitor the entire associated automation process live, in addition
to motion control. To prevent that everybody can see
into the production via camera, specific MachineApps can be
adapted directly in the control platform via an extended HMI
interface (Human Machine Interface) and access can be restricted
based on user rights or group membership.
Motion system unrestrictedly configurable
The gantry system shown on the stand consists of two linear
actuators with a flexible joint on each axis, connected to a
plate as a bridge. This demonstrates our gantry configuration
capability by allowing the actuators to rotate the entire gantry
bridge in differential mode. The system is controlled with
Aerotech’s Automation1 controller. “We use our new gantry
control with Automation1 to demonstrate how decoupling
control of the axes is made possible,” explains Simon Smith.
“In doing so the decoupling method performs a coordinate
transformation and converts the two physical linear axes into
a logical linear axis (R) and a logical rotary axis (Theta). The
You can also control a rotational movement (yaw)
on the yaw axis (Theta) via the decoupling control
when working with a flexible gantry
The trade fair demo shows the high flexibility of the Automation1
to control the Theta rotary axis, which can be used
for small alignments of the bridge and thus contributes to the
flexibility of the gantry system.
Simon Smith adds: “We will also present the auxiliary func -
tions of Automation1 that allow the user to set up the control
very easily and quickly.” One example of these auxiliary
functions, he says, is the setup of the homing routine, where
the home position can be automatically set to the center of
the travel range and the system calculates this automatically
after moving from limit to limit. This saves the user a lot of
time when installing and setting up the motion solution.
further information: www.aerotech.com
no. 4, November 2023
45

components
Efficient tool handling by hand
New tool separator for tools up to 2.5 tons
Goodbye chisel and hammer and hello to the new
kind of manual tool handling! RUD Tecdos TSB (short
for Tool Separator Bench) is the name of the latest
innovation from RUD Ketten Rieger & Dietz GmbH
und Co. KG located in Aalen, Germany. With the RUD
Tecdos TSB opening and closing tools weighing up to
2.5 tons is now particularly quick and simple, and can
be done simply by hand.
That’s right, entirely without additional gripping tools. Cool
for the workflow in the injection moulding industry: the
opened mould halves can be cleaned and serviced directly
on the tool separator – thanks to the 360 ° rotation function.
RUD Tecdos TSB is already the fourth RUD innovation for
efficient tool handling. The specialist is thus further expanding
its RUD Mould Handling Solutions division and once
again establishing itself as a solution provider for integrated
mould handling.
“Moulds and tools weighing up to 2.5 tons present many
users in the injection moulding industry with a dilemma:
they are too heavy for manual opening and closing, but the
use of larger auxiliary equipment is not efficient either. With
the Tecdos TSB we offer an adequate solution for efficient
and safe opening and closing,” explains Anne Kühling, product
manager in the Conveyor & Drive division at RUD Ketten
Rieger & Dietz GmbH & Co.
RUD Tecdos TSB for tools up to 2.5 tons
The new Tecdos TSB tool separator facilitates manually guided
and controlled opening and closing, entirely without the use
of gripping tools or additional electrical, pneumatic, or hydraulic
energy. Light and medium-weight moulds can be
opened and closed easily, quickly, safely, and ergonomically
by hand, using only the two sliding plates. Time-consuming
disassembly of hoses, connections and other components is
not necessary.
The Tecdos TSB is available in two versions with different
sized plates of 60 x 30 cm or 80 x 40 cm. Thanks to the low
working surface of 31 cm, working on the new tool separator
is particularly ergonomic.
Optimized workflow and top efficiency
The sliding plates have a special feature in store: they are not
only movable, for opening and closing the moulds and tools,
but can also be rotated by 360 °. This allows the opened mould
halves to be rotated vertically around their own axis – for easy
inspection, cleaning, and maintenance directly on the work
surface of the mould opener. By means of a locking mechanism
the plates can be fixed in place for maintaining the tool.
46 no. 4, November 2023

components
Tecdos TSB can be operated simply, safely, and quickly
by just one person. “With our latest innovation, we not only
shorten handling times, but also the operating time of the
employees for a doubly optimized process in tool handling,”
emphasises Kühling. Thanks to its low weight and compact
dimensions, the new Tecdos TSB can be used flexibly
throughout the factory.
Mould handling solutions
RUD offers the right solution for every stage of work in tool
handling. The Tecdos TM is simply made for the maintenance
and repair of moulds and tools up to 64 tons. It turns and rotates
tools and moulds weighing several tons – and all within
a minute. The Tecdos TS tool separator opens and closes
injection moulding, stamping and forming tools weighing up
to 10 tons in just a few seconds. The Tecdos TS requires a maximum
of five minutes for the entire opening process, thereby
revolutionising processes in production, maintenance and
repair.
Like the new Tecdos TSB, the Tecdos TMB industrial workbench
is designed for tools and moulds weighing up to 2.5
tons. With the 2-in-1 combination of industrial workbench
and turnover device, light and medium weight injection
moulds can not only be turned efficiently and safely, but also
serviced directly on site. “Together with our Tecdos TMB,
our new Tecdos TSB offers an ideal combination of tool turner
and tool separator,” says Kühling.
Process optimisation and occupational safety:
the demand is high
When handling moulds and tools weighing several tons, or
lighter ones, a lot can be gained by working efficiently and
safely, especially in maintenance and servicing. It not only
saves time and costs, but also pays into the occupational safety
of the employees and protects the infrastructure in the
companies.
RUD has witnessed in recent years how great the need for
process optimisation and occupational safety is, especially
in the injection moulding industry. “Ten years ago we developed
our first innovation, the Tecdos TM turning table.
Our other solutions following within the last three years. For
all four developments – Tecdos TM, Tecdos TS, Tecdos TMB
and most recently Tecdos TSB – the impetus came directly
from the market,” clarifies Kühling. “For us it is therefore
only logical to focus our Mould Handling Solutions division
even more strongly and to expand it further”.
further information: www.moldhandling.rud.com
New standard clamping devices
EMUGE adds the EvoGrip centering vises and the
EvoPoint zero-point system to its product range. The
new product category complements the portfolio of
customized solutions for special applications with
standard clamping devices for universal applications.
The EvoGrip centering vises are manually operated direct
clamping devices that clamp the workpiece centrically.
They convince with high clamping forces up to 75 kN combined
with high accuracy. The compact design compared to
the possible workpiece size offers ideal accessibility and allows
the use of short tools for reduced vibrations and higher
cutting values. Clamping devices of this type can be used universally
thanks to the compact design. Geometrically optimized
guidings minimize spreading of the clamping jaws.
The centering vises are designed for automated part and
handling of clamping equipment.
EvoPoint group
EvoGrip
The combination with the EvoPoint zero-point system enables
a modular, very lean system design and the reduction
of set-up times by up to 80 %. Flexible adaptation systems
are available for existing zero-point systems, machine
tables, swivel brackets, cubes and pyramids. The centering
vises can be converted accordingly for clamping large parts.
The new clamping devices are also available in pneumatic or
hydraulic versions. They can also be customized for automation
solutions.
further information: www.emuge-franken.com
no.4, November 2023
47

components
Door opener to hydraulic expansion technology
The TENDO Silver stationary toolholder is the ideal introduction to
hydraulic expansion technology and offers an excellent price/performance ratio
At EMO 2023, SCHUNK presented a new toolholder
– the TENDO Silver. It offers the perfect introduction
to tool clamping using hydraulic expansion technology
and scores as a precision all-rounder.
Since a long time users in metalworking have been won over
by the benefits of hydraulic expansion technology in toolholders:
tools are clamped via a hydraulic mechanism where,
on inserting a screw, the internal pressure medium is compressed
and the expansion sleeve elastically deformed. This
way the tool shank is tightly enclosed. The high tension ensures
absolutely secure holding of the tool and precise runout
accuracy of less than 0.003 mm. The outcome of this technology
is optimum workpiece surfaces, avoidance of micro
chipping, protection of the machine spindle and a longer
tool service life. The technological trick is the inner oil cushion
which is highly effective in damping vibrations that occur
during machining. Hydraulic expansion technology is also
far superior to other technologies in terms of sustainability
since it is long-lasting, energy-saving and resource-conserving
in use. The TENDO Silver from SCHUNK’s economy
segment provides users with an all-rounder which, in addition
to its technological advantages, is also highly impressive
due to its outstanding price-performance ratio.
Low-cost entry to hydraulic expansion technology
As an inventor and market leader in the field of hydraulic expansion
technology, SCHUNK has now acquired 40 years of
experience in this technology. Application-specific, differentiated
segmentation of toolholders means customers receive
appropriate hydraulic expansion toolholders according to
their application and requirements. The goal is economical,
efficient and resource-saving machining of parts, which users
of the TENDO series have appreciated for decades now. The
toolholders come finely balanced as standard and are suitable
for high speeds. The tool shanks can be clamped directly into
the toolholder – making the TENDO series, with its micrometer-accurate
tool changes in seconds, a genuine hit. Users
thus save on set-up time and can dispense with additional
peripheral equipment. They benefit from a high degree of
flexibility since, in addition to direct clamping, clamping of
different diameters with slotted or coolant-proof intermediate
sleeves is also possible. The permanent precision runout
accuracy and effective vibration damping ensure metalworkers
a long tool service life and thus cost savings, because
frequent regrinding or new procurement is no longer
necessary.
The TENDO Silver completes the toolholder family in the
economy segment as a precision all-rounder that is compatible
with all machine tool spindles. With its polished surface,
the hydraulic expansion toolholder in DIN contour
is dirt and rust repellent and is available in eight different
interfaces.
further information: www.schunk.com
48 no. 4, November 2023

components
Tool management made easy
As a world premiere, the HAIMER
Hybrid Chuck was presented exclusively
at EMO. This new and patented technology
combines the advantages of two
clamping worlds – the vibration-damping
properties of a hydraulic chuck with
those of a high-precision, high-performance
shrink fit chuck.
The new Micro Collet Chuck, which was also
making its debut at EMO, is suitable for shank
diameters from 1 mm and meets the customer’s
requirement for maximum runout
accuracy combined with the simplest possible
handling.
New software for shrink fit,
balancing and presetting machines
In the future all HAIMER shrink fit, balancing
and presetting machines will receive a
new software version that includes a bidirectional
interface that can be connected to the
new Tool Room Manager (TRM). This new
software monitors the online status of all
devices in the tool room, documents the
processes and monitors compliance with the
specified tolerances.
An optional OPC-UA interface, client or
MQTT Connect interface standardizes access
to machines, devices and other systems
and enables manufacturer-independent data
exchange.
On the Tool Dynamic balancing machine
the new software opens the door to automatic
indexing also. For this purpose a small gripper
is integrated in the new models, which
rotates the tool to be balanced. The software
does the rest without any further manual intervention
of the operator.
For the Tool Dynamic Preset Microset combination
unit, the Automatic Drive function
enables fully automatic measuring.
Automation Cube ONE
Smart tool management
Another highlight at EMO was the new integrated
Tool Management System including
Smart Vending Machines. Within the very
short time of only four months the software
WinTool, including the dispensing system
Toolbase, was implemented in the companies
own manufacturing plant with full integration
to the machines. Also additional functions have been enabled in the
software and a new digital process was standardized.
To offer its customers an optimal tool data management and tool dispensing
system, the company cooperates with the TCM Group and its product
lines WinTool and Toolbase. As a software solution for tool and data management,
WinTool enables the management of tools, resources, machine programs,
processes and master data. Toolbase is a smart tool dispensing system
that includes individually configurable tool cabinets and software. It enables
efficient access management via barcode, RFID or manual interaction.
In the future all Microset presetting devices can be equipped with WinTool
as a standard.
Future concept for tool presetting
While all these innovations make the manufacturing process easier for every
machinist and can also be used by small and medium-sized companies to increase
efficiency, the highlight at the booth was mostly aimed at companies
with the highest degree of automation. Talking about the new Automation
Cube One, which can shrink out and in a tool in 60 s, measure it and transfer
the data to the machine and to databases.
Managing director Andreas Haimer explains: “We have learned from our
‘Automation Cube’ pilot project in recent years. In line with customer requirements
our new robotic cell is built as massively as a machine tool. For
this purpose we have brought various partners on board. Siemens supplies
the latest SINUMERIK ONE CNC control. Without the full, fast and highly
competent support from Siemens we would not have been able to realize this
new machine within a record time” emphasizes Andreas Haimer.
further information: www.haimer.com
no.4, November 2023
49

components
Mould and die suite
Empowering teams to make short work of complex manufacturing
Hexagon’s Manufacturing Intelligence division
released HxGN Mould & Die, a suite of dedicated
CAD/CAM (computer-aided design and manufacturing),
engineering and automation tools empowering
mould and die and tool manufacturers to increase efficiency,
reduce costs and produce high quality tools for
their customers across industries ranging from automotive
to aerospace and beyond.
The suite was developed to empower mould designers and
makers to achieve operational excellence in the design and
manufacturing of plastic injection moulds, progressive dies,
forming dies and similar tools.
Capabilities of the suite include CAD/CAE (computeraided
design and engineering) for plastic injection mould
design, CAD/CAE for progressive die design, CAD for manufacturing
preparation, CAM for CNC (computer numerical
code) machine-tool programming, process simulation and
G-code verification and optimisation, shop-floor production
intelligence and automation and collaboration powered by
Nexus, Hexagon’s digital-reality platform. The suite’s simulation
tools help manufacturers understand the feasibility and
cost of mould-making processes with actionable information.
“We took everything we know about mould-and-die manufacturing,
including our best-in-class Hexagon technologies,
to build a specialized suite that empowers mould and
die shops of any size to get the best results faster,” said Chuck
Mathews, general manager, production software at Hexagon.
“Their competitive edge will be enhanced by Nexus, which
connects desktop software via the cloud to provide further
automation and collaboration opportunities. It also gives
teams an easy way to share 3D models with customers through
secure web-based visualisation, and consolidate access to
libraries for tooling, fixtures, and materials from their desktop
apps.”
“The HxGN Mould and Die suite is an exciting development,
combining our customers’ challenges with our deep
domain knowledge to achieve more. We are refocussing innovation
to bring our ecosystem technologies together and
help production teams to make better informed decisions,
faster,” added Parth Joshi, chief product & technology officer
at Hexagon.
For plastic-injection mould manufacturers the suite provides
tools for design and engineering, flow simulation,
reverse engineering, automated electrode design and CNC
machining. It builds upon Hexagon’s market-leading VISI
and WORKNC software, providing comprehensive multiaxis
CAM programming capabilities, direct modelling of solids
and surfaces and supports the construction, editing and
repair of complex 3D geometry. Reverse engineering tools
allow mould makers to efficiently create solid models from
scanned data – a crucial capability for mould repair and
redesign and for creating solid models for manufacturing
when CAD files are not available.
The suite also provides plastic flow analysis tools that help
shop-floor teams produce cost effective and reliable moulds
that will perform as required. These powerful simulation
capabilities are simple to use, which ensures that non-engineers
or less experienced employees achieve optimal results.
The creation of intricate or difficult-to-machine injection
mould features is further simplified with the automated
design and simulation of EDM (electrical discharge machining)
electrodes and their associated holders.
For progressive die manufacturers, HxGN Mould and
Die offers a connected workflow with tools for design and
engineering, simulation and production. It enables the stepby-step
unfolding of surface and solid models, which gives
designers more control over the development of each forming
stage. Flexible strip layout capabilities and the ability
to simulate the performance of the strip at any stage in the
design process make it easy to quickly analyze the results
of design changes. The software also helps manufacturers
predict springback and offers compensation strategies when
challenges with material performance are identified.
The suite supports shops in fully utilising advanced
machine tools, using trusted Hexagon VISI and WORKNC
software to help programmers optimize machining cycles
and specialized cutting strategies specific to mould production.
Prior to machining, CNC programs can be simulated
and verified using NCSIMUL, the suite’s G-code simulation
software, which incorporates the entire machining environment
to generate an effective digital twin of the machinery,
part and processes.
further information: www.hexagon.com
50 no. 4, November 2023

impressum
ISSN 2628-5444
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Adelbert Haas GmbH ................................................ back cover
Aerotech GmbH ........................................................page 13
CERATIZIT Deutschland GmbH ................................ inside front cover
Kapp GmbH & Co. KG ..................................................page 11
Lach Diamant Jakob Lach GmbH & Co. KG .............................front cover
no. 3, August 2023
51

SMPLY
PRDC MR
FFCNTLY
Efficiency can only be achieved by sustainable
optimization, requirements are constantly growing,
and everything is getting fstr and fstr and evn fstr.
Relaax. At Adelbert Haas, we will be looking at
innovative solutions at GrindDialog 2023.
GrindDialog: 09–10 November 2023 in Trossingen
Save the date, register and benefit immediately:
www.grinddialog.com
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www.multigrind.com