hpt 2024 #1

ISSN 2628-5444 

high precision tooling 

Machine Tools, PCD, PVD, CVD, CBN, Hard Metal 2024 – 1 

■ Development of customized diamond coatings ■ Process visualization system in the semiconductor industry ■ 

■ Extreme surface finish for e-mobility ■ Optimized chamfering of internal gears ■ It was only this little spark ■

»CONTOUR PROFILED« 

Diamond and CBN wheels 

show the claws 

U2 no. 1, February 2024 

tradition.passion.innovation 

www.lach-diamant.de 

office@lach-diamant.de 

100 years of diamond and CBN tools 

® 

®

editorial 

Eric Schäfer 

editor-in-chief 

Nothing is impossible 

This was the slogan of a well-known car manufacturer until it gradually became common parlance. 

Today, these words are often used to indicate that someone has accomplished something that seems 

almost impossible. Nothing is impossible is also the title of the article on page 42, which is about 

“Optimized chamfering of internal gears during the machining process”, which opens up 

new possibilities in gear manufacturing. In the course of e-mobility, transmissions have undergone 

massive changes in terms of design and tolerances. Here, as in medical technology, perfect surfaces 

are a challenge. 

When the highest surface qualities in the micrometer range are required, grinding is often the method 

of choice, as shown in the user reports in this issue of hp tooling. They already give a small foretaste 

of the upcoming GrindingHub, the new hub of international grinding technology. 

Making the impossible possible has always characterized users of precision tools as well as their 

manufacturers. Sometimes all it takes is a small spark to change the world of machining, 

as Horst Lach vividly describes in his review of the history of LACH DIAMANT. 

If you take a closer look at the “materials & tools” section, you will see how diverse the possibilities 

are for finding the right cutting material and the perfect tool geometry for new, demanding machining 

tasks that were previously impossible to realize. These range from extremely hard CBN tools for 

machining brake discs to customized, extremely hard and wear-resistant diamond coatings for 

machining materials such as CFRP, graphite and aluminum alloys to ultra-hard PCD cutting materials 

for machining ceramic materials. In short, to make the the impossible possible. 

Eric Schäfer 


no. 1, February 2024 

3

table of contents 

cover story 

Hybrid manufacturing strategy for reverse shoulder prosthesis component 

Developed and tested 6 

materials & tools 

Extremely hard grade for strong brakes 10 

Development of customized diamond coatings 12 

Multi-edged PCD tools for machining technical ceramics 14 

New end mills for volume machining of aluminum materials 15 

processes 

High-end surfaces of gears for electromobility 32 

written by Janis Thalau and Dr.-Ing. Philip Geilert 

Benefit from tried-and-tested grinding technology 34 

Complete solution for grinding and eroding 36 

Automated cutting edge optimization of stamping and forming tools 37 

machining center 

Swiss quality as a price leader 38 

A benchmark in cutting performance and precision 40 

Optimized chamfering of internal gears during the machining process 42 

New peripheral and double T-land grinding machine for the European market 43 

components 

Innovative cutting oils for non-ferrous metal processing 44 

Support-free 3D printing opens up new applications and reduces waste 45 

New precision clamping fixture simplifies turning and milling processes 46 

High-performance coolant filtration for consistent quality in the production of mini tools 48 

Ultra black laser marking for medical technology 50 

news & facts 17 

fairs 5 

impressum & company finder 51 

4 no. 1, February 2024

fairs in alphabetical order 

AMB Stuttgart, Germany 

(September 10-14, 2024) 

bauma Shanghai, China 

(November 26-29, 2024) 

CMTS Toronto, Canada 

(Sept. 29-Octob. 2, 2025) 

EPHJ Geneva, Switzerland 

(June 11-14, 2024) 

FABTECH Toronto, Canada 


FEIMEC São Paulo, Brazil 

(May 7-11, 2024) 

current status 

2024 


2025 




FILTECH Cologne, Germany 


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 


METALEX Bangkok, Thailand 


SIAMS Moutier, Switzerland 


SIMTOS Seoul, South Korea 


sps Nuremberg, Germany 


Stone+tec Nuremberg, Germany 


Surface Stuttgart, Germany 

Technology (June 4-6, 2024) 

TIMTOS Taipei, Taiwan 

(March 3-8, 2025) 

TMTS Taichung, Taiwan 

(March 27-31, 2024) 



2025 


2025 









2025 


trade fair dates as by end of January 2024; we are not responsible for reliability of these dates 


5

cover story 

Hybrid manufacturing strategy for 

reverse shoulder prosthesis component 

Developed and tested by Mikron Tool and DMG MORI 

The development specialists at Mikron Tool in Agno, partnering 

with DMG MORI and supported by Motorex’s cooling lubricant experts, 

have developed a hybrid process to optimize the manufacture 

of a “glenoid base plate” (titanium component of a reverse, cementless 

shoulder prosthesis). 

This was completed in a three-step process: solid base machined on a millturn 

machining center, implant post printed on 3D SLM machine, and final 

machining completed on a traditional vertical 

machining center. The hybrid process has the 

potential to become well established in prosthesis 

production. Compared to other manufacturing 

processes, there are economic and 

qualitative advantages. 

Mikron Tool, DMG MORI and Motorex 

have tested and compared different methods 

for manufacturing the complex component 

of a titanium shoulder implant (see figures 

1 & 2). 

• machining with subsequent coating 

(hydroxyapatite or titanium coating) 

• additive construction with post-machining 

on a machining center 

• and their combination: hybrid production 

1. base plate turned from 

solid, milled, drilled 

2. surface coating 

built up additively 

3. post-processing on 


This manufacturing process was presented 

at the Mikron Tool Technology Center 

in Agno during the 2023 Medical Days (see 

figure 8, page 8). 

The required production steps were carried 

out using the following machines: 

figure 1 

Production process: 

1. machined base plate 

2. hollow pin designed with additive manufacturing and 

implant surface for osseointegration 

3. profiling and thread milling on the machining center type DMP 70 

figure 2 

Shown here is the 

glenoid base plate 

produced using the 

hybrid process, which 

delivers outstanding 

quality and return 

on investment 

1. two-shift pre-machining on the NTX 1000 

2. three-shift continuous additive 

manufacturing on the 

LASERTEC 30 DUAL SLM 

3. single-shift post-processing on the 

DMP 70, using milling, drilling, and 

thread cutting 

1. Complex geometry – 

specific surface structure 

The geometry of the glenoid base plate is complex. 

Ti-6Al-4V ELI titanium is a challenging 

material to machine. The implant’s surface 

facing the shoulder blade must be porous 

to give the bone material the best opportunity 

for ingrowth. A hollow pin in the center of 

the glenoid base plate is attached to the glenosphere 

using a press fit. It serves as a primary 

anchorage for the prosthesis in the bone and 

requires a specific surface for osseointegration. 

Depending on the implant design, the 

anchoring can be reinforced with a central 

screw, which is guided through the hollow pin 

(see figure 3). 


cover story 

2. Perfectly aligned interfaces 

Combining CNC machining and additive 

manufacturing presented several challenges 

to the Mikron Tool and DMG MORI specialists. 

It was crucial to develop an optimized 

workflow for the various production steps and 

perfectly coordinate the individual machines’ 

productivity to ensure the desired final quality 

while maintaining high efficiency. 

figure 3 

Estimates from the USA suggest that the demand for shoulder prosthesis will 

increase by 2030 threefold in the group of under 55 years old and eightfold in the 

over 55 years old; the aging population aims to maintain a high quality of life 

in old age, leading to a worldwide increase in reverse shoulder prostheses 

Parts programming with the interfaces 

between additive and machining production 

plays a key role here. The combination of the 

CNC software “Esprit” and the 3D printing 

software “Celos” enables seamless integration 

of additive and machining production. 

2.1 Raw data for 3D printing can be 

transferred directly into the 

CNC program 

Thanks to the software solutions, users can 

transfer the raw data for 3D printing directly 

into the CNC program. Because of this they 

are able to change elements such as surfaces, 

design and supporting structures. 

figure 4 

A custom-fit base plate guarantees optimum positioning accuracy 

during laser melting 

figure 5 

Processing the highly reactive titanium powder requires strict safety measures 

and trained staff throughout the production process 

figure 6 

Laser melting of the hollow pin and the implant surface takes 10 h 16 min. 

For areas that need to be reworked, the user 

specifies the dimensions so that they can be 

optimally processed subsequently. Due to the 

flexibility of this stage, the customer gains 

multiple benefits that include pro cesses consistency, 

decreased cycle time, and increased 

reliability, resulting in a repeatable and safe 

process. 

3. Process progression: 

1. machining 

2. SLM 3D printing 

3. finishing by machining 

Based on the results of the previous series 

of tests (machining and 3D printing), the 

manufacturing specialists decided first to 

produce the flat base of the glenoid, including 

the screw holes and a central hole with 

a thread, from solid material using carbide 

tools (“Crazy Tools”) on the mill-turn center 

NTX 1000. 

The second step involved building the hollow 

pin and the required implant surface 

directly on the flattened surface of the prefabricated 

base using a laser melting process 

(see figures 4-6). This approach was chosen to 

reduce the amount of used material and the 

production time. An additional advantage: 

final post-machining on the DMP 70 machining 

center was significantly reduced compared 

to additive manufacturing alone. From 

this stage only the profiles and thread on the 

hollow pin were required to be finished (see 

figure 7, next page). 


7

cover story 

figure 7 

Dr. Alberto Gotti, head of R & D at Mikron Tool, 

explains the necessary post-machining steps of a 

hybrid-manufactured medical device workpiece 

figure 8 

Daniel Schmid, senior technical sales support at Motorex and 

Marco Cirfeta, head of marketing & sales Europe at Mikron Tool, 

during a tour of the production facilities 

3.1 Challenging preparation phase 

Optimizing the production flow required utilizing the full 

capacity of the LASERTEC 30 DUAL SLM, which enabled 

the simultaneous production of 56 semi-manufactured forms. 

A specially developed component support was used as base 

structure, fitted with the appropriate number of customized 

pockets to accommodate the glenoid bases. 

3.2 Accurate positioning of the base 

for 3D printing 

The parts had to be carefully screwed to the support plate 

to ensure maximum precision during 3D printing. For this 

purpose, a thread was added in the middle of the glenoid 

base plate, which was manufactured with the NTX 1000. To 

ensure even and precise alignment of the base plate on the 

support plate, an additional guide groove was added. The 

corresponding form was located in the mould cavities. As a 

result it was possible to precisely define the angular position 

of the parts. 

3.3 With a positioning accuracy of 50 µm 

Once the base plate had been secured in the pressure chamber 

of the LASERTEC 30 DUAL SLM, it was crucial to determine 

the exact position of the base on which the material 

was to be applied. Precise adjustment of the lasers is essential 

for accurate material application, hence a calibration process 

is required: 

➤ First, the exact zero point of the machining area is 

determined. This point serves as a reference for 

all subsequent positioning and processing. 

➤ Second, automatic referencing is set for moving 

the laser head to the predefined positions. 

➤ Third, a coordinate measuring device checks the actual 

positions of the workpieces, detects deviations and 

generates corresponding correction data to ensure 

high-accuracy positioning. 

Calibration ensures that laser processing meets the highest 

quality standards and that the printed parts comply with 

the desired specifications. In the example case, the arranged 

components achieved a positioning accuracy of 50 µm. 

Regarding part handling: for the next step the support 

plate with 56 parts was clamped directly into the DMP 70 

machining center for final post-machining. 

The hybrid manufacturing process developed at Mikron 

Tool’s application center has been designed to achieve an output 

of 560 parts per week, using the three machines: millturn 

center, 3D SLM and milling center (see figure 9). 

Let’s review the machining steps and the number of shifts 

required: 

step 1: pre-machining on the NTX 1000 in two shifts 

step 2: 3D printing on the LASERTEC 30 DUAL SLM 

in three shifts 

step 3: finishing on the machining center DMP 70 in 

one shift (see figure 10). 

Here the comparison with 

other manufacturing processes 

Mikron Tool and DMG MORI specialists compared this 

manufacturing method with the two traditional manufacturing 

processes: 

➤ machining with subsequent coating for osseo-integration 

➤ and full 3D selective laser melting with 

secondary finishing 

The hybrid manufacturing process for the shoulder prosthesis 

developed by Mikron Tool and DMG MORI is the 

most cost-effective and produces the highest quality product. 

Anyone interested in the study can contact the Mikron Tool 


cover story 

Turning and milling center Additive manufacturing SLM 5-axis machining center 

figure 9 

Hybrid production chain for producing a glenoid base plate made of titanium Ti6AI4V ELI; 

titanium alloys are a considerable challenge both in machining and in additive manufacturing 

development and application center directly. There is also a white paper 

available that describes the three processes in detail and shows their advantages 

and disadvantages. 

4. Conclusion: the hybrid process ensures perfect coordination 

The series production process developed by the manufacturing experts from 

Mikron Tool, DMG MORI and Motorex leads to perfect coordination of the 

three involved machines, maximizes their capacity utilization and is characterized 

by a high degree of material utilization. Component handling was 

reduced to a minimum and the desired quality targets for the medical technology 

component were achieved in exemplary fashion. 

If we compare hybrid manufacturing within a one-thousand-unit batch, 

the cost savings compared to the listed traditional methods are: 

4 % compared to machining with coating and 

9 % compared to complete additive process with post-machining 

There is no doubt that additive manufacturing 

will significantly impact many production 

processes of the metalworking in the future. 

One of the prime benefits of this technology 

will be design and manufacture shapes and 

geometries that are currently not available for 

traditional methods. 

The economic success of combining additive 

manufacturing and machining depends on 

the specific requirements of the component. 

In this project, the excellent characteristics 

of the additively manufactured implant surface 

proved advantageous. Not only is it more 

durable, but its structure is also considerably 

more stable than applied coatings. 

Compared to machining, the dimensional 

tolerances of laser melting technology are 

smaller, which is why the need for post-processing 

steps cannot be completely ruled out. 

In fact, the precision of CNC machining is 

much more accurate, reaching values of up 

to 0.005 mm. In addition, the machining processes 

offer greater repeatability and excellent 

surface qualities. 

Nevertheless, the new hybrid process will 

set new standards, both in terms of technology 

and cost efficiency. 

figure 10 

The hybrid-manufactured medical device components require only a minimum 

number of post-machining steps; machining the parts in a single clamping process 

is friction-locked and highly efficient 

further information: 

www.mikrontool.com 

www.dmgmori.com 

www.motorex.com 


9


Extremely hard grade for strong brakes 

Horn is launching a new product range 

for the economical machining of brake disks 

Horn is launching a new product range for the economical 

machining of brake disks. This includes solid 

CBN ISO inserts and solid CBN-tipped full radius and 

shaped inserts. In addition to the inserts, stable tool 

carriers round off the product range. 

“With the performance of the grade, we can almost bring a 

lathe to its knees,” says Horn product manager for ultra-hard 

cutting materials, Aribert Schroth. The talk is about cubic boron 

nitride (CBN), or solid CBN to be precise. The grade has 

no metallic bonding phase and therefore has the highest hot 

hardness of all cutting materials. In addition, the abrasion resistance 

increases compared to CBN substrates. Solid CBN is 

mainly used for cast iron machining. 

In addition to the inserts, 

stable tool carriers round 

off the product range for 

the economical 

machining of 

brake disks 

Cutting speeds of well over 1,000 m/min (3,280.84 ft/min), 

depths of cut of several millimeters and feed rates of up to 

0.7 mm/rev (0.028"/rev) are typical when machining brake 

discs made from cast materials. The tool system used must 

be able to keep up and, above all, last a long time. The tool 

life requirements are high due to the price per cutting edge of 

solid CBN. Depending on the operation and metal removal 

rate, well over 1,000 brake discs can be machined per insert 

corner. Horn offers two different tool solutions for machining 

the heat compensation groove of a brake disc. The tipped 

S117 profile grooving insert is ideal for large batch production 

in terms of speed and long tool life. During the process, 

the groove is produced in just under two seconds in a single 

operation. For greater flexibility, the company provides 

S229 tipped full radius inserts. They offer the option of copy 

turning the heat compensation groove in about four seconds. 

Regrinding and re-tipping are possible with both types. 

For further machining applications on a brake disc, Horn 

offers a solid full CBN ISO S insert with eight cutting edges. 

In conjunction with the tool holder the tool system is suitable 

for roughing and finishing. The neutral design of the inserts 

fully utilizes the number of cutting edges. This means 

that eight cutting edges per ISO insert are available for most 

turning operations. The tool holder combines important 

criteria: the frictional connection between the carbide thrust 

pad and the insert occurs via a defined annular surface. This 

prevents compressive stresses on the CBN insert. Engagement 

of the thrust pad in the bore of the insert pulls it into the 

insert seat of the tool holder with a secondary force. This 

prevents clamping errors and increases precision. 

further information: www.horn-group.com 



New product lines provide versatility, 

value in wide variety of machining applications 

fiberboard (MDF), melamine, laminates, particleboard, stone, 

concrete and other difficult-to-machine applications. 

“The extension of Hyperion’s PCD portfolio offers more 

flexibility to our customers in choosing the right material for 

each job they pursue, all from one trusted and credible supplier,” 

said Hilary Interrante, Hyperion’s segment manager of 

Diamond Solids. “Our aim is to support our partners as the 

PCD tooling industry evolves.” 

Hyperion Materials & Technologies, a leading 

manufacturer of hard and super-hard materials for 

a variety of demanding industrial applications, is 

excited to announce the launch of two new polycrystalline 

diamond (PCD) lines, the P-Series and 

U-Series, that expand the company’s offering to the 

toolmaking industry. 

“Both product lines maximize value for performance and 

feature a higher level of quality consistency than is offered 

elsewhere due to Hyperion’s advanced quality control techniques 

that ensure the highest level of integrity for every 

blank shipped,” said Karl Tuffy, general manager of 

Hyperion’s Diamond business unit. “Hyperion is excited to 

offer these new product lines alongside its industry-leading 

premium COMPAX® PCD line.” 

P-Series PCD is specially designed for tools used in machining 

nonferrous and nonmetallic workpieces for automotive, 

aerospace, electronics and other precision applications 

that demand consistent performance and long-term 

cost savings. P-Series PCD delivers outstanding results 

across a diverse range of workpieces, including aluminum, 

metal matrix composites, copper, carbon-fiber-reinforced 

polymers (CFRP) and other precision applications. 

U-Series PCD is explicitly designed for tools used in 

machining nonferrous and nonmetallic workpieces in 

woodworking, heavy machinery and other utility applications. 

This product line enables toolmakers to optimize 

costs without sacrificing reliability in machining applications 

where competitiveness and consistency are critical. 

Suggested applications include, wood, medium-density 

The P-Series and U-Series PCD lines are offered as discs with 

a 62 mm usable area and as cut tips in either standard shapes or 

to customer drawings. Learn more about P-Series and U-Series 

PCD by visiting Hyperion’s PCD product pages. 

further information: www.hyperionmt.com 

TRUST IN 

TECHNOLOGY 

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for e-mobility gears compared to 

conventional components - 

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Development of 

customized diamond coatings 

With its in-depth knowledge in the field of coating technology, MAPAL also develops extremely hard and 

wear-resistant diamond coatings for machining materials such as CFRP, ceramics, graphite and aluminum 

alloys. MAPAL’s machining solutions thus achieve longer tool lives and more process reliability especially for 

applications in the automotive and aerospace industry, in the die & mold sector and in medical technology. 

Inside view of a reactor during the HF CVD coating process 

The tool manufacturer has coating technologies 

at its site in Aalen and in its centers of 

competence to coat indexable inserts and 

solid carbide tools using PVD or CVD processes. 

The choice of process depends on the 

relevant application parameters. For dry machining 

and high cutting speeds usually CVD 

is chosen; in the case of unstable machining 

situations or difficult machining conditions, 

the tougher PVD coatings are applied. 

If adhesive wear processes occur frequently 

when machining, the use of diamond-like 

carbon coatings (DLC) is advisable. DLC 

coatings are also deposited using PVD or a 

plasma- enhanced CVD process. These coatings 

are formed by a mixture of sp 2 hybridized 

carbon atom bonds (graphite) and those with 

The homogeneous CVD diamond coating from MAPAL ensures long tool lives and 

a high level or process reliability, for example with the OptiMill-Composite-Speed- 

Plus solid carbide milling cutter for CFRP workpiece materials 

SEM image of the break edge of a 

diamond-coated solid carbide tool 

(3,000x enlarged) 



sp 3 hy bridization (diamond). The mixing ratio determines 

the physical and mechanical properties of the coatings. The 

more sp 3 atomic bonds, the harder the coating. 

New coating processes thanks to 

CVD diamond reactors 

Pure diamond coatings are required for milling or drilling 

highly abrasive materials. The process used in the MAPAL 

Group for the synthesis of diamond coatings is a modification 

of purely thermal CVD and is called hot filament CVD, 

or HF CVD for short. Conventional CVD coatings are not 

suitable for coating shank tools because the tool lengths and 

the high coating temperatures usually result in length distortion. 

In HF CVD, wires made of refractory metals heat up a 

mixture of hydrogen and methane to temperatures of up to 

2,500 ° C. In the process very reactive methyl radicals are 

formed, which are gradually deposited on the seeded carbide 

surface as a diamond layer. The company has own CVD diamond 

reactors at its disposal. 

“In recent years we have worked extensively on improving 

the diamond coating process and have created new 

possibilities for MAPAL in tool production”, explains 

Dr. Martin Kommer, team leader R&D Cutting Material / 

Coating at the company. The tool manufacturer has the complete 

tool design now under its own control, from the appropriate 

geometry to the selection of a suitable carbide to the 

coating. This means that tools can be designed even more 

precisely to meet customers’ requirements. The development 

department in Aalen has its own center for machining, which 

tests new tools for tool life and wear behavior, among other 

things. 

Since the coating process functions via a chemical reaction 

combined with mechanical clamping, defined etching of the 

carbide surface and seeding are important during pre-treatment. 

As not every carbide is suitable for this, MAPAL evaluates 

appropriate substrates. Whether fine-grained microcrystalline 

or nanocrystalline layers are produced during coating 

is determined by the temperature, pressure and flow of the 

respective reactive gases during the process. 

Theoretically, layers up to a thickness of 50 µm can be produced 

by HF-CVD. For coating its tools, the company currently 

focuses on the range between 3 µm and 15 µm, depending 

on the respective application. 

The optimized HF CVD process produces layers with almost 

uniform thickness, which MAPAL used when developing 

its OptiMill-Composite-Speed-Plus. In the respective 

machining application, the entire cutting edge length can 

thus be reliably used regardless of the cutting depth. 

further information: www.mapal.com 

Milling competence 

right down the line 

■ 45° Milling - Smooth cut and high metal 

removal at extremely smooth running 

■ 90° Milling - Highest productivity, cost 

reduction and optimal distribution of cutting 

force 

■ HFC-Milling - High metal removal under the 

most difficult conditions 

■ 3-D Milling - Universal applicable tool 

system for mould and die 

■ Solid carbide milling - Over 1000 products 

for every application 

www.boehlerit.com


Multi-edged PCD tools for 

machining technical ceramics 

Workshop sample component and cutters and drills 

used from the MARLIN tool series 

In recent decades there has been fundamental 

change in the world of ceramic materials. The variety 

of different compositions influence the properties of 

ceramics depending on their intended use. 

How ever, two characteristics make the processing 

of these materials especially difficult: their high 

degree of hardness and their brittleness. In the past 

this necessitated the use of complex production 

methods. Grinding and polishing processes were often 

employed. 

ZECHA has recently developed an innovative solution for exactly 

this type of material. State-of-the-art laser technology 

is used to create previously impossible tool geometries from 

ultra-hard cutting materials such as PCD and CVD. 

Thanks to the use of lasers, these geometries can be designed 

to be even more delicate, precise and intricate. 

In addition many more cutting edges can be applied to the 

tool, especially with small tool diameters. A 0.6 mm torus 

cutter with 42 cutting edges is just one example of the many 

possibilities offered in our 3D-Marlin series brochure. 

A higher number of cutting edges means a better distribution 

of cutting force, less heat generation and an increased 

tool life. It is helpful that the MARLIN-3D series internal and 

shank cooling, which also minimizes friction and tool wear. 

All of this contributes to our goal of achieving great surface 

quality and process reliability. 

Successful workshop raises the profile of ceramic 

milling: A new approach to micro-machining 

In May 2023, ZECHA and its main partners organized a 

seminar at the Teisnach University of Applied Sciences to 

highlight both the challenges of ceramic machining and the 

performance of this new generation of tools. 

In addition to presentations on the material properties of 

technical ceramics by Teisnach University, tool selection by 

ZECHA, programming by OPEN MIND and machine technology 

by Röders and WESCHU, there was also a live machining 

demonstration. A total of forty participants from 21 

companies were particularly impressed by the measurement 

results from Teisnach University. 

➢ surface roughness Ra in the nanometer range 

➢ minimal shape deviations from CAD 

➢ flatness in the µm range 

➢ chipping in the µm range 

The success story continues: workshops upcoming 

The success of the Teisnach seminar means that it will be organized 

again! In November 2023, another purely ceramic 

workshop was held in the Allgäu Regio, once again focusing 

on micro-machining. Further workshops on this topic are 

also planned for 2024 in German-speaking areas so the industry 

can be kept up-to-date with the latest ceramic milling 

developments. Moreover, ZECHA will also be present at the 

ceramitec trade fair in April 2024 with its own stand. 

further information: www.zecha.de 



New end mills for 

volume machining of aluminum materials 

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 

The Alu-Cut “Aerospace” WF series from 

FRANKEN’s 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 was designed 

to machine wrought aluminum alloys and cast aluminum 

alloys with a silicon content of up to 7 %. There are also GLTcoated 

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 and 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. In addition to 

the end mills fitted with a chamfer, the product line is supple- 

The Alu-Cut “Base” product line is available as 

end mills with chamfer and in versions with corner radius 

mented by different variants with corner radius in order to 

always have the suitable tool available for the specific requirements 

on the component. 

The existing geometries are supplemented by the 0 14 and 

18 mm. In addition there are two new lengths: 3.5 x D and 

6 x D. 

further information: www.emuge-franken.com 


15


The new kid in town 

It’s official! SPR Abrasives GmbH, located south of 

Berlin, has been founded. SPR Abrasives is the result 

of a collaboration between three well-known companies 

in the superabrasives industry. 

Despite their great differences these companies can create 

enormous synergies by working together. Their different 

activities, interests, geographical locations and backgrounds 

can strengthen each other. It certainly helps that the owners 

and employees have known each other for years or even 

decades and that there is already a strong mutual trust. 

The basic outline of the company was established back in 

January 2023 and has been gradually expanded in recent 

months. Decisions were made about the product range, and 

production areas and machines were ordered and set up. Production 

(plating) is ready to start in the first quarter of 2024. 

What can customers expect from SPR? 

The first products available will include CBN powders, resin 

and metal bond powders, in both mesh and saw grit sizes. 

The required micron powders will also be offered and SPR 

will distribute natural diamond powders. 

All abrasives first undergo a fusion process in the company’s 

own facilities south of Berlin. They are then sieved 

and tested for strength. Then they can be coated with the desired 

metal to meet individual customer requirements. Despite 

this additional quality boost, the entire product range is 

offered at competitive prices. SPR works closely with its customers 

to develop customized coatings and continually pushing 

the boundaries of innovation to find the ideal solution. 

SPR also offers a number of exclusive services. Customers 

can have products, that they have purchased elsewhere, or old 

stock, cleaned or screened and subjected to the same rigorous 

testing in SPR’s laboratories. An important service is reclaim, 

where customers can recover their powders used in electroplating 

from waste liquids. This allows to reuse materials, 

which is considerably cheaper than buying new powders. 

Furthermore, SPR’s product range includes a wide variety 

of polycrystalline diamond and CBN (PCD and PCBN) as 

well as CVD diamonds, single crystal synthetic diamonds, 

and HPHT diamonds. The company is proud to offer customi 

za tions to cover special laser and wire EDM cutting 

needs and to supply to customer’s specifications. 

The power of partnership 

SPR is the result of a collaboration between three companies 

in the superabrasives industry. They are three complete 

different companies, each with its own identity, its own 

approach and its own product focus, spread across three countries 

and two continents. But it is precisely these differences 

that make their collaboration so strong. VDiamant’s laboratory 

and production facilities for testing and manufacturing 

abrasive powders are unparalleled in Europe. Gemmata 

has been a global player in the field of industrial natural diamonds 

for decades, while American Superabrasives is one of 

the largest distributors of superabrasives, powders and solids 

in the United States. 

All three partners have a large customer base worldwide 

with rela tively little overlap. There is an excellent relationship 

between the three of them so everyone knows “who does 

what” and the different team members complement each 

other perfectly and do what they love to do! As a result of all 

these factors SPR will undoubtedly become a strong player in 

the superabrasives market. The combined expertise in sourcing, 

production, marketing, customer relations and laboratory 

services will enable SPR to make a significant and lasting impact 

in the world of superabrasives. 

Each partner will also act as a representative SPR office for 

their own local markets, ensuring that all customers have a 

known point of contact in their own place of business. 

further information: www.sprabrasives.com 


news & facts 

Experience the future of 

connectivity live in Shanghai 

Interested parties in China, too, can now explore 

umati more fully, and experience the benefits of open, 

standardized OPC UA-based inter-faces live and in 

person. The joint connectivity initiative of the VDW 

(German Machine Tool Builders’ Association) and 

VDMA (German Mechanical Engineering Industry 

Association) opened the “Smart IoT in Production” 

showroom in Pudong near Shanghai, China, in 

November 2023. 

The event was attended by deputy consul general Lukas Meyer 

of the Consulate General of the Federal Republic of Germany 

in Shanghai, representative Yugang Zhao of the Free Trade 

Zone Administration and numerous invited guests. Dr. 

Alexander Broos, head of Research and Technology at the 

VDW (German Machine Builders’ Association), Frankfurt 

am Main, and umati project manager, is delighted with the 

new possibilities opened up by the showroom: “The future of 

connectivity is digital – but sometimes a physical platform is 

needed: a place where people can share ideas and products 

can be presented. The showroom highlights in tangible form 

the benefits of umati – in China, one of the most important 

and largest markets for the industry.” 

The showroom is a joint facility of the VDW and the operator 

of the IMT (International Machine Tool Center) in the 

Pilot Free Trade Zone, where the VDW already has its local 

office. 

In future companies can present their smart production 

technology to the public and meet potential customers and 

partners at these premises covering a total of roughly 500 m 2 . 

Permanent exhibition stands can be hired for this purpose. 

The first exhibitors include the Chinese subsidiaries of 

Liebherr-Verzahntechnik from Kempten and the United 

Grinding Group from Bern, Switzerland. David Feng, head of 

the Gear Cutting Machines & Automation Division at Liebherr-Verzahntechnik 

in China, one of the first companies to 

About the VDW 

The German Machine Tool Builders’ Association (VDW), 

headquartered in Frankfurt am Main, has been the mouthpiece 

of the German machine tool industry for more than 130 years. 

It represents its members’ interests vis à vis the political and 

scientific communities, business partners and the general 

public, both nationally and internationally. In addition to 

offering many valuable services to its members, the VDW has 

been organizing trade fairs for the industry for over 100 years. 

It stages various events which carry the “VDW trade fair” 

seal of approval. These include: EMO Hannover (next fair 

September 22-27, 2025) which it runs on behalf of the 

European machine tool association Cecimo, and GrindingHub 

(next fair May 14-17, 2024) together with Messe Stuttgart. 

Until 2022 it organized also the METAV in Düsseldorf, 

International Trade Fair for Metalworking Technologies. 

Official opening of the “Smart IoT in Production” showroom 

in Shanghai in November 2023 

(source VDW) 

hire an exhibition stand in the showroom: “The ‘Smart IoT in 

Production’ showroom in Shanghai offers Chinese industry 

an application scene with real time capability. This will help 

local industrial users to experience first-hand how umati can 

help them meet the future challenges of smart manufacturing 

trends.” 

umati has a permanent exhibition stand which it uses 

to present the possibilities of open data networking based 

on OPC UA. It also serves as a basis for cooperation with 

Chinese companies and the local connectivity initiative, NC 

Link. An intelligent caliper from Mahr, Göttingen, and a 

marking laser from Trumpf, Ditzingen, are being integrated 

into the umati dashboard in order to provide a live demonstration 

of networking from China. Georg Fischer Machining 

Solutions, Schaffhausen, Switzerland, also connected a machine 

in a live demonstration. Deputy consul general Lukas 

Meyer emphasizes the importance of umati: “There is currently 

a lot of buzz surrounding Industry 4.0, making it now 

all the more important to ensure full transparency. With its 

powerful network of partners and its international approach, 

umati is laying important groundwork here. The ‘Smart IoT 

in Production’ showroom represents a further important way 

for the network to raise its profile.” 

Broos also emphasizes the global aspect of the showroom 

in China: “The dashboard is the same as the one used in the 

rest of the world. This offers further proof that there is no reason 

for the consistent implementation and use of open data 

interfaces to stop at national borders. Connectivity is a global 

issue in mechanical engineering.” The showroom is open to 

all companies based in the IMT as well as all umati partners 

in China. It can also be used as an event location. Anyone 

interested can find out more at the following address: 

https://umati.org/dcs/ 

further information: www.umati.org 


17

news & facts 

Cutting tools inspire creativity and brilliance 

The ANCA Tool of the Year Awards marked its sixth 

year with a record attendance of hundreds of industry 

professionals at the awards ceremony and gala dinner 

held at EMO Hannover. 

EMUGE-FRANKEN, a renowned German cutting tool 

manu facturer, took first prize for their multi-functional carbide 

tool infused with ceramic material, promising extended 

tool life and unparalleled performance. 

JG Group from Poland secured first place in the Virtual 

Tool Category for the second consecutive year with an impressive 

simulation of a Dachshund – or more commonly 

known as the sausage dog, that used 24 profiles just to create 

the head of its character. 

EMUGE-FRANKEN’s multi-functional carbide tool 

infused with ceramic material 

Machinist’ category at ANCA. Recognizing women who are 

choosing to enter our industry is paramount, and we extend 

our heartfelt congratulations to Lena, the deserving winner 

of this historic category.” 

further information: www.anca.com 

Finalists 

This year’s awards held a special significance as ANCA announced 

Lena Risse from Risse Tool Technology GmbH as the 

winner of the inaugural Female Machinist of the Year award. 

This initiative aims to promote diversity in the cutting tool 

industry and provide positive role models for women and 

girls considering careers in this sector. 

Pat Boland, ANCA Co founder said: “This year has been 

marked by exceptional enthusiasm, boasting an impressive 

array of entries and showing a remarkable complexity in the 

design of both real and simulated tools. The competition was 

fierce, but EMUGE-FRANKEN, a globally renowned cutting 

tool manufacturer hailing from Germany, has truly set itself 

apart. Their combination of ceramic materials and tungsten 

carbide posed a significant manufacturing challenge and 

effectively extended the performance and lifespan of the cutting 

tools.” 

“JG Group’s whimsical ‘sausage dog’ entry added a delightful 

touch to the competition, underscoring the remarkable 

flexibility of our software and the impressive results that can 

be achieved when blending creativity and expertise. Moreover, 

we were honored to introduce the inaugural ‘Female 

Made on ANCA 

winner: EMUGE-FRANKEN 

Their winning entry was a complex, multi-functional cutting 

tool with edges consisting of carbide and ceramic material. 

Using iGrind to its fullest, this tool makes the most of the 

profile software’s flexibility, employing layers and segments 

to assign operations efficiently. Demonstrating exceptional 

precision in profile measurements and 3D edge radius 

measurements, the tool closely aligns with its intended 

specifications and stands out for its accuracy. 

second place: ARCH Cutting Tools 

ARCH Cutting Tools continues to create another outstanding 

multi-functional cutting tool with the required accuracy. Once 

again, it proves to be a functional tool to replace multiple 

processes, thanks to its use of profile software, segments and 

other iGrind operations during its creation. The cutting edges 

exhibit consistent 3D edge radius and good levels of profile 

accuracy. 

third place: TDM Cutting Tools 

This tool has been designed to replace multiple processes, 

and it’s the result of combining profile software, segments, 

and various iGrind operations. With its profile and edge 

radius meeting satisfactory standards, it’s worth noting 

that this is a complex tool overall. 


130 years ago, Hermann 

Heller opened a trading 

and manufacturing 

company for patented 

products and 

watchmaking tools in 

Nürtingen. 

With the business selling 

tools of all kinds, the engineer 

laid the foundations 

for the long- term 

success of the company, 

which entered the mechanical 

engineering sector 

in 1898 with the pro - HELLER production in 1967 

duction of cold circular 

saws for metal cut ting 

and the ma nufacture of 

blade skiving and thread 

cutting machines. In 1900, Hermann Heller’s brother Ernst, a 

trained tradesman, joined the company, marking the birth of 

“Gebr. Heller Werkzeug- und Maschinenfabrik” in Nürtingen. 

Hubert and Berndt Heller as 

managing directors of the machine factory 

In the 1960’s, Hubert and Berndt Heller took over the manage 

ment of the machine factory and developed the company 

into an internationally successful group of companies with 

numerous locations in all major markets – including the production 

plants in England (Redditch) and Brazil (Sorocaba), 

which will be celebrating their 50 th anniversaries this year. 

However, not all was plain sailing for HELLER. “The era of 

the economic miracle was over and we now had to assert ourselves 

in the field of tension between economic fluctuations 

and tougher competition,” recalls Berndt Heller, HELLER’s 

HELLER is 130 years old 

news & facts 

long-standing CEO and 

former chairman of the 

super visory board, at the 

beginning of his management 

career in the family 

business. The brothers’ 

instinct for innovation 

was the key to success in 

difficult times and times 

of crisis. With the development 

of modular machining 

centers and Flexible 

System Transferlines 

(FST) in the 1990’s, they 

led the company out of 

HELLER production today one of the most serious 

crises in its history, putting 

it back on track. “We 

achieved this with the 

help of our employees, 

who have always given their best – even in what has sometimes 

been difficult circumstances. They deserve my utmost 

respect and have played an important role in the company’s 

130-year history,” Heller continues. 

Looking to the future with a spirit of 

tradition and innovation 

To this day the Heller family has maintained the spirit of a 

family-run business with a strong sense of tradition. Since 

2016 all shares in the group have been wholly owned by the 

family. Berndt Heller’s children, Nicole Pfleiderer and Marc 

Heller are shareholders in the company. The group is currently 

managed by Dr. Thorsten Schmidt (CEO), Andreas Müßigmann 

(CFO), Dieter Drechsler (COO) and Peter Weber (CSO). 

further information: www.heller.biz 

Platinum Tooling now offering 

Hommel+Keller QUICK catalog 

Platinum Tooling, the importer and master distributor 

of live tools, angle heads, marking tools, Swiss 

tools and multi-spindle tools manufactured by various 

global suppliers, is the North American importer 

of the QUICK knurling and marking tools from 

Hommel+Keller. They have just released the full tooling 

catalog. 

Hommel+Keller manufactures the QUICK line with a combination 

of function and innovation. Quality, precision and stability 

are the key principals used to make QUICK® tools successful. 

Furthermore the company prides itself on a rich history 

of providing customized solutions for its customers. 

Benefits of cut knurling include maximum precision and 

surface quality, knurling of thin-walled components without 

deformation and time savings due to faster cutting speed 

and feed rate. Additional advantages are machining of virtually 

all materials (including gray cast iron and plastic), zero 

or only minimal alternation of the workpiece diameter and 

minimal surface compaction. 

In form knurling, machining of the workpiece by cold 

forming compresses the surface of the workpiece. Knurling 

is possible up to a workpiece shoulder, at any position of the 

workpiece of the inner and end faces as well as conical. All 

knurling profiles according to DIN 82 can be produced. 

QUICK also has knurling tools with interchangeable jaws 

and knurling wheels available from stock. Wheels with special 

dimensions and pitches can be customized. 

QUICK marking tools can mark workpieces in seconds 

and on a wide variety of geometries independent of workpiece 

diameter. They are ideal for machines with small installation 

space and can mark up to a shoulder. 

further information: www.platinumtooling.com 


19

news & facts 

Stronger pre-sales support for the European market 

Following the successful debut after its name change 

to DN Solutions at EMO Hannover last September, 

DN Solutions is now taking its customer support in 

Europe to a new level: with the opening of its first 

Technical Center in Germany. 

With this expansion, the machine tool manufacturer is 

strengthening its pre-sales support in the European market. 

The Center in Dormagen, North Rhine-Westphalia was officially 

opened November 22. 

With the grand opening of its Technical Center in North 

Rhine-Westphalia, DN Solutions underlines its growth strategy 

in Europe and its market position as one of the world’s 

largest manufacturers of CNC machine tools. More than 200 

partner customers and guests attended the two-day opening 

ceremony at the end of November. The event kicked off 

with speeches from Kim Wonjong, CEO of DN Solutions, and 

Stefanie Frank, CEO of Siemens MTS. 

Various automation solutions and 

machining demonstrations 

The Center, spanning an impressive 1,000 m 2 , features a 

range of cutting-edge facilities. At the opening ceremony the 

company gave visitors live demonstrations of twelve ultramodern 

CNC machines on the showroom floor. The focus 

was on advanced automation solutions in collaboration with 

various specialized automation suppliers. Visitors were able 

to see the seamless integration of various advanced machining 

solutions for themselves: 

➤ the compact turning center (PUMA DNT2100), 

which is equipped with a collaborative robot, 

➤ the two-spindle horizontal turning center 

(PUMA TW2600M), which is integrated with a 

gantry loader, and 

➤ the compact vertical 5-axis machining center 

(DVF 4000) with automatic workpiece changer (AWC) 

DN Solutions also presented industry-orientated machining 

solutions – e.g. for aerospace and electric motors – in conjunc- 

With the new Technical Center in Dormagen DN Solutions 

is strengthening its pre-sales support in the European market 

At the opening ceremony DN Solutions gave visitors 

live demonstrations of twelve ultra-modern CNC machines 

on the showroom floor 

tion with clamping solutions and advanced machining technologies 

such as dynamic turning. 

Clear focus on customer service 

DN Solutions has set itself the goal of improving its pre-sales 

service. The new Technical Center serves as a consulting 

hub for interested parties, who can find out about suitable 

machine tools and their peripherals. Companies can test the 

machining process on request, including a time study and 

machining. For this purpose, at least ten different machine 

types – with a special focus on high-end machines – will be 

on permanent display even after the opening. The Center also 

has a design workshop, a spindle reconditioning center, and a 

spare parts warehouse. 

The Technical Center has far-reaching, long-term goals. It 

will expand its role to serve as a technical hub for turnkey 

projects, develop its automation retrofit department and 

become a reliable one-stop solution provider for everything 

related to customers’ manufacturing. Technical seminars 

for customers and partners will also be organized regularly 

throughout the year. 

Closer to the European market 

“Both the Technical Center and the planned research and 

development center are the first of their kind in Europe,” said 

Kim Wonjong, CEO of DN Solutions. “In a market as dynamic 

as Europe, where numerous cutting-edge technologies like 

Industry 4.0 and additive machining are evolving, our presence 

in the region is pivotal. These centers will not only 

enhance our understanding of the European market but also 

enable us to cater to its unique needs and evolving trends. 

We are confident that this move will not only strengthen 

our foothold but also foster valuable connections with our 

European customers.” 

further information: www.dn-solutions.com 


news & facts 

Expansion of sales and support activities in Austria 

Okuma is further expanding its operations across Europe. The 

well-known CNC machine tools manufacturer acquired the 

Austrian company, precisa CNC-Werkzeugmaschinen GmbH, with 

effect January 1, 2024. 

The Vienna-based company will now operate under the name Okuma 

Austria GmbH and focus on improving customer service and sales. 

“As the exclusive sales partner for Okuma in Austria for over 35 years, 

precisa CNC-Werkzeugmaschinen has been a significant key to our success 

there. Now that it is our wholly owned subsidiary, we can continue and expand 

our business. We firmly believe that combining resources and expertise 

will lay the groundwork for a prosperous future”, says Norbert Teeuwen, 

Okuma Europe’s managing director. Standardized sales and service processes, 

including pre-sales and after-sales support, will provide even faster support 

and access to the most up-to-date technologies, solutions and knowledge, 

resulting in maximum customer efficiency and performance. The long-term 

experience of the employees and management from former precisa CNC- 

Werkzeugmaschinen GmbH is particularly important in this regard. “We 

are thrilled to be able to rely on their expertise for future growth and new 

innovations”, adds Norbert Teeuwen. 

further information: www.okuma.eu 

Anton Köller, precisa; Sabine Wank, precisa; 

Norbert Teeuwen, Okuma (left to right) 

An overall positive year for the 

italian machine tool manufacturing industry 

2023 has been another positive year for the Italian manufacturing 

industry of machine tools, robots and automation systems, which 

has achieved a new production record, thus extending the favourable 

trend that should also be confirmed in 2024. 

This is in short what was outlined by Barbara Colombo, president of 

UCIMU- SISTEMI PER PRODURRE, the Italian machine tools, robots and 

automation systems manufacturers’ association, during the usual year-end 

press conference. 

Based on the preliminary year’s data processed by the Studies Dept. & 

Business Culture of UCIMU-SISTEMI PER PRODURRE, 2023 production 

reached 7,560 mil €, marking a 3.8 % increase over the previous year. The 

result was driven by the good performance of exports, which grew by 10.3 % 

to 3,825 mil €. The export/production figure went up again, attaining 50.6 %. 

On the foreign front, according to UCIMU processing of the data from the 

Italian National Statistics Institute (ISTAT), in the period Jan-August 2023 

(latest available data), the main destination markets for the Italian product 

offering of the sector were the United States (356 mil €, + 26.7 %), Germany 

(217 mil €, + 8.8 %), China (163 mil €, + 34 %), France (138 mil €, + 32.1 %) and 

Poland (128 mil €, + 14.7 %). 

On the other hand, the deliveries by Italian manufacturers in the domestic 

market decreased slightly to 3,735 mil €, 2 % less than in 2022. Deliveries and 

imports – the latter down by 4.5 % to 2,385 mil € – were affected by the decrease, 

however slight, in consumption, which dropped by 3 % to 6,120 mil €. 

For 2024 the Italian machine tool, robot and automation manufacturers 

expect a consolidation of the results achieved in recent years: production 

should be driven by foreign demand, whereas 

a moderate reduction should be recorded in 

domestic consumption. 

According to the forecasts from the Studies 

Dept. & Business of UCIMU, 2024 production 

should grow to 7,595 mil € (+ 0.5 % compared 

to 2023), thanks to the rise in exports, which 

should stand at 4,070 mil € (+ 6.4 %). 

Deliveries by manufacturers to the domestic 

market should not exceed 3,525 mil € (- 5.6 %), 

in line with the drop in domestic consumption, 

which should reach 5,780 mil € (- 5.6 %). 

Imports should also be affected by the 

reduced demand for investments in Italy, falling 

by 5.5 % to 2,255 mil €. The export/ production 

figure should rise again, standing 

at 53.6 %. 

Barbara Colombo commented: “Although 

there are clear signs of a slowdown, the 2023 

of Italian manufacturers is closing with a posi - 

tive sign; the ‘Made in Italy’ production of 

the sector grew again, setting a new record 

thanks to the good results obtained by Italian 

enterprises abroad”. 

further information: www.ucimu.it 


21

news & facts 

Machine tool industry 

expecting decline in production 

In 2024 the German machine tool industry is expecting production 

to decline by almost 3 % to 14.8 bill. € in nominal terms. “A nominal 

record volume of 17 bill. € was posted in 2018/2019, and five years 

later there is still no sign of this figure being matched,” said Franz- 

Xaver Bernhard, chairman of the VDW (German Machine Tool 

Builders’ Association), at the association’s annual press conference in 

Frankfurt am Main, Germany. 

There has been a clear slowdown in orders since the beginning of last year, 

which is now having an increasing impact on sales and production. The 

considerable order backlog, representing around eleven months’ work, had 

helped. However nearly all supply bottlenecks have since been resolved, allowing 

the backlog to be worked through more quickly. Accordingly orders 

on hand are less and less able to compensate for the lack of new orders. Overall, 

orders fell by 10 % in nominal terms in 2023. The decline was partly offset 

by several months of stronger project business. Domestic demand fell by 

14 %, almost twice as much as foreign demand. 

The global economy is unlikely to provide much impetus in 2024. The 

growth rates of both gross domestic product and investment are once again 

down on the previous year’s levels. 

The international purchasing managers’ index also highlights the weakness 

of the global economy in all key markets, particularly in the Eurozone 

and Germany. 

“In fact, we are currently seeing two divergent developments,” reported 

Bernhard. Growth sectors such as electric vehicles, wind power, medical 

technology, aerospace and defense boosted the project business in particular, 

while the standard machine business performed more weakly. Small and 

medium-sized customers such as job shop businesses are uncertain about 

the future and are reluctant to invest. Machine purchases are also more difficult 

to finance due to higher interest rates. Companies that prepared for the 

transformation process at an early stage are therefore better able to weather 

the weak demand. 

2023 ended with an overall good result 

Last year production is estimated to have risen by just under 8 % in nominal 

terms, to 15.2 bill. €. In real terms this represents an increase of 2 % due 

to inflation, which remained at a high average level over the year. Exports 

grew by 9 %. The export ratio reached almost 70 %. Exports were boosted 

Franz-Xaver Bernhard 

by double-digit growth in America. Asia and 

Europe on the other hand, only recorded 

single-digit increases. The US in particular 

saw extremely dynamic growth, driven above 

all by investment in climate protection and 

renewable energy. China, by contrast, experienced 

weak growth due to falling consumer 

demand and the ongoing difficulties in the 

real estate sector. India, on the other hand, enjoyed 

sharp upward growth. At 5 % domestic 

sales did not increase quite as much. This is 

attributable in part to the weaker demand 

from domestic customers. 

further information: www.vdw.de 

GLOBAL INDUSTRIE 2024 

Paris Nord Villepinte will be the meeting place for the 

whole industrial ecosystem March 25-28, 2024. 

As a symbol of reindustrialization, GLOBAL INDUSTRIE 

provides companies with concrete solutions by engagement 

of bringing together and uniting the whole of industry, its entire 

ecosystem, its value chain and its user markets for four 

days. With this GLOBAL INDUSTRIE responds to the multiple 

challenges facing industry (the environmental and ecological 

transition, recruitment, social and societal responsibility 

training, financing, industry 5.0, etc.) to ensure that 

France remains a land of investment and innovation. 

A showcase for regions and know-how, the fair will host 

2,300 exhibitors, spread across 15 sectors, all of whom can be 

contacts to develop a business and create new synergies with 

investors or suppliers in order to build tomorrow’s industry. 

Demonstrations and experiments can be seen at the biggest 

fair in France with more than 1,500 machines, displaying 

cutting-edge innovations and industrial processes, showing 

the trends and signals that will transform tomorrow’s industry. 

The GI Awards, for their part, will highlight the most 

innovative discoveries identified among exhibitors. 

further information: www.global-industrie.com 


news & facts 

Executive board member 

Thierry Wolter retires after 30 years 

CERATIZIT has reallocated responsibilities on the 

executive board as of December 1, 2023. Following 

the planned retirement of executive board member 

Thierry Wolter from the operational business, the executive 

board will consist of three members in future: 

Melissa Albeck, Andreas Lackner and Frank Thomé. 

“Thierry Wolter has been one of the defining personalities of 

the company over the last 30 years and has made a decisive 

contribution to making CERATIZIT one of the world’s largest 

carbide manufacturers today,” comments Karlheinz Wex, 

chairman of the supervisory board, on Thierry Wolter’s role 

in the company’s history. Born in Luxembourg, he was the 

most prominent face of the company, particularly in the cutting 

tool sector, and represented CERATIZIT nationally and 

internationally in numerous organizations. 

Wolter sees his entrepreneurial legacy in good hands. “After 

30 years it is time to pass the torch to the next generation. 

CERATIZIT has come a long way since the merger in 2002 

and I am firmly convinced that with the energy, ideas and 

commitment of the employees we will succeed in becoming 

one of the three largest carbide manufacturers in the world in 

the coming years,” says Wolter. 

Three executive board members 

As part of the ongoing integration of the Plansee Group, the 

three CERATIZIT executive board members are also taking 

on overarching tasks. For example Andreas Lackner is not 

only responsible for production in all CERATIZIT divisions. 

As a member of the executive board of the Plansee Group, he 

is also responsible for the strategic core topic of sustainability 

for the entire Plansee Group. 

Melissa Albeck, Andreas Lackner, Frank Thomé (left to right) 

Advancing internationalization 

Melissa Albeck is now responsible for the sales of cutting 

tools, which was previously the responsibility of Thierry 

Wolter. She is also responsible for CERATIZIT’s American 

business on the executive board. The board trio is completed 

by Frank Thomé. His responsibilities include sales for the 

hard material solutions and global tungsten & powders divisions 

as well as the company’s Asian business, including the 

CB-CERATIZIT joint venture. 

This gives Albeck and Thomé a key role in the company. 

In order to continue to grow faster than the market and become 

the number 3 in the carbide industry, it is planned to 

focus on growth in Asia and on the American continent in 

the coming years. 

further information: www.ceratizit.com 

Change in management at VOLLMER KOREA 

Sharpening specialist VOLLMER, based in southern 

Germany, has appointed a new managing director of 

the VOLLMER KOREA subsidiary in Seoul. Jooma 

Park assumed the position of managing director from 

Song Ho Hwang in spring of 2023. 

Song Ho Hwang started working for VOLLMER in South 

Korea in the early 1990’s as a dealer under the company name 

“Palma Trading”. In 2016, Song Ho Hwang played a major role 

in establishing VOLLMER KOREA and was responsible for 

the very successful development of the Seoul-based subsidiary. 

He retired March 2023. 

In Jooma Park an experienced expert and connoisseur of the 

Asian tool market is taking over the running of VOLLMER 

KOREA. He joined VOLLMER about a year ago and has 

shown great commitment in familiarizing himself with his 

new position as managing director. At the same time as this 

change in management, the 

subsidiary also moved into 

its new premises in Seoul. 

The VOLLMER site in South 

Korea employs three people. 

“My goal is to sustainably 

expand the business of 

VOLLMER sharpening machines 

in South Korea and 

to even more firmly establish 

our services and digital 

solutions in the tool manufacturing 

industry,” says 

Jooma Park. 

further information: 

www.vollmer-group.com 

Jooma Park 


23

news & facts 

UNITED GRINDING opens a 

subsidiary in Southeast Asia 

The UNITED GRINDING Group has been present in 

the Southeast Asian region for many years through 

representatives and the WALTER EWAG Asia Pacific 

subsidiary. Now the specialist for grinding, eroding, 

laser and measuring machines bundles and intensifies 

its activities in this region by founding a group 

subsidiary in Singapore, United Grinding Asia Pacific 

Pte. Ltd. 

“Southeast Asia is a strategically very crucial region for us. 

Establishing a UNITED GRINDING subsidiary is the logical 

step to intensify our activities in this region,” explains 

Stephan Nell, CEO of the UNITED GRINDING Group. 

The potential is high, and the number of customers is continuously 

increasing. “Proximity to our customers has always 

been important to us to ensure fast and uncomplicated 

support,” adds Nell. The ability to offer the group’s bundled 

technology and application know-how from a single 

subsidiary offers customers 

many advantages. 

Michael Schmid, CEO of the 

new UNITED GRINDING 

branch and already responsible 

for the Southeast Asian 

business of the WALTER and 

EWAG brands for more than 

20 years, adds: “We can bundle 

the strength of our powerful 

team in the joint group 

Michael-Schmid 

subsidiary and serve our customers even better. In the future, 

we will offer all three group technologies, surface and profile 

grinding, cylindrical grinding and tool machining, under 

one roof. I am convinced that bundling and intensifying our 

activities in this region is a win-win for all parties involved.” 

further information: www.grinding.ch 

Unlocking sustainable advantages 

Harnessing solar power for a green future 

Weiler Abrasives, a global provider of abrasives, 

power brushes and maintenance products for surface 

conditioning, is thrilled to announce a major leap toward 

sustainability with the initiation of two photovoltaic 

systems at its Maribor and Zreče manufacturing 

facilities, commencing operations in October 2023. 

These photovoltaic systems represent a significant commitment 

to harnessing clean, renewable solar energy, aligning 

with Weiler Abrasives’ dedication to environmental responsibility 

and sustainability. The installation is designed to contribute 

up to a fifth of Weiler Abrasives’ electricity requirements 

in its Slovenian facilities and, as a result, decrease 

nearly 900 tons of CO 2 emissions annually through climatefriendly 

solar energy. 

“The combined output of this impressive 1,839 kWp solar 

power installation is remarkable, generating electricity equivalent 

to the demand of around 1,000 households. This initiative 

significantly reduces greenhouse gas emissions, equivalent 

to removing 500 medium-sized cars from the road annually,” 

explains Rok Mezgec, director – supply chain and 

R&D at Weiler Abrasives. “As a founding member of the 

Sustainable Abrasives Association of Europe (SEAM), Weiler 

Abrasives is committed to the industry’s shared goals on 

three key pillars of sustainability: environment, society and 

business. By implementing this project our company is putting 

sustainability at the forefront and recognizing it as a 

competitive advantage in the industry.” 

Jože Kaligaro, managing director of Weiler Abrasives 

EMEA, commented on the importance and strategic significance 

of the systems in place. 

“The project of constructing the photovoltaic systems is 

undoubtedly of particular importance in the implementation 

and strengthening of the sustainable development activities 

of the Weiler Abrasives Group, especially because of 

the economic and environmental impact it brings and the 

knowledge and experience that our teams of experts have acquired 

in its implementation. The latter means forming new 

development nuclei for the search and implementation of 

the sustainable projects that lie ahead. It is already clear that 

in the future the successful implementation of sustainable 

projects will be the key point of differentiation between 

successful and unsuccessful companies in the long term,” 

Kaligaro says. 

“At Weiler Abrasives we believe that it is our responsibility 

to take meaningful steps toward mitigating our environmental 

impact. The introduction of these photovoltaic systems 

marks a significant milestone in our sustainability journey,” 

states Arjang “AJ” Roshan-Rouz, Weiler Abrasives CEO, at 

the official launch of the systems. “By embracing renewable 

energy solutions, we not only reduce our carbon emissions 

but also demonstrate our dedication to fostering a cleaner, 

more sustainable future for our community and the planet.” 

Weiler Abrasives remains steadfast in exploring further 

opportunities to minimize its environmental footprint, 

embracing innovative technologies and sustainable practices. 

Implementing these photovoltaic systems reflects the com 

pany’s dedication to sustainability and environmental responsibility, 

embodying the company’s commitment to making 

a positive difference in the world. 

further information: www.weilerabrasives.com 


MAPAL Group mourns Dr. Dieter Kress 

news & facts 

Dr. Dieter Kress passed away 

on December 27, 2023, at the 

age of 81 after a long illness. 

He was a passionate entrepreneur 

and an impressive personality. 

Dr. Dieter Kress was 

at the helm of the MAPAL 

Group for almost five decades. 

He shaped the once small company into an international 

company group. 2018 he retired from active management, but 

continued to take a lively interest in the company’s developments. 

“MAPAL is my baby and that’s why I will never let it 

out of my sight completely,” he once said. The entire workforce 

joins the Kress family in mourning the passing of Dr. 

Dieter Kress. 

Dr. Dieter Kress joined MAPAL Dr. Kress KG in 1969 

after graduating with a degree in mechanical engineering 

and business administration. His father Dr. Georg Kress had 

founded the company in 1950. While working at the company, 

Dr. Dieter Kress completed his doctorate on the subject of 

reaming, which was the basis for the success story of MAPAL. 

Dr. Dieter Kress developed high-performance special tools 

from the standard reamer product. This also became the 

essence of MAPAL – always close to the customer to find the 

best solution for him and his machining. 

With great vision and personal commitment Dr. Dieter 

Kress managed the company for 49 years as president. The 

product portfolio was continuously expanded under his leadership 

and MAPAL established itself on the market as a fullrange 

supplier. Tools for drilling, countersinking, milling, 

hard turning and boring were added to the reaming range. 

Chucks and devices for setting, measuring and dispensing 

as well as numerous tool-related services further expanded 

the portfolio. 

In addition, company acquisitions and foundations were 

responsible for MAPAL’s enormous growth. Dr. Dieter Kress 

followed his very own strategy. For him it was important to 

respect and preserve the respective culture of the acquired 

companies. In his 49 years at the helm, Dr. Dieter Kress 

transformed a regionally active manufacturer of taps into an 

internationally active, broadly positioned company group. 

Dr. Dieter Kress 

Today, MAPAL is represented in 

44 countries and employs around 

5,000 people worldwide, including 

around 1,700 at headquarters 

in Aalen. In 2018 Dr. Dieter Kress 

handed over responsibility to his 

son Dr. Jochen Kress, who is now 

the third generation to run the 

precision tool manufacturer. 

In addition to his entrepreneurial activities Dr. Dieter Kress 

was also involved in a number of honorary positions. The 

region and the training of young people were particularly 

close to his heart. He attached great importance to training 

junior staff directly at MAPAL and invested in the corresponding 

infrastructure. Today MAPAL is one of the largest 

training companies in the East Württemberg region. There 

are as many as 300 apprentices at MAPAL worldwide, about 

130 learning different professions at MAPAL in Aalen – from 

cutting machine operators to warehouse logistics specialists 

and IT specialists. 

Dr. Dieter Kress also supported research and education at 

the Aalen University – among other things by setting up an 

endowed chair in cooperation with other companies and as 

a member of the university council. He was active in committees, 

initiatives and associations, including as chairman 

of the VDMA Precision Tools Association and as a founding 

member of the P.E.G.A.S.U.S. association, which supports 

company founders. 

Dr. Dieter Kress has received numerous awards for his services, 

including the Cross of the Order of Merit of the Federal 

Republic of Germany and the Golden Staufer Medal of the 

state of Baden-Württemberg. He was also one of the first recipients 

of the German Mechanical Engineering prize. Aalen 

University confer him the dignity of honorary senator. 

The MAPAL Group and its employees owe a great deal to 

Dr. Dieter Kress. He has shaped, developed and promoted the 

company and its employees as the driving force and motor. 

It is with great gratitude and deepest sympathy for his 

family that the shareholders, management, works council 

and employees take their leave. 

further information: www.mapal.com 


25

news & facts 

LACH DIAMANT – 100 Years 

Tradition. Passion. Innovation. 

part 8: 

It was only this little spark that brought 

the cutting world to its current glory… 

“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) 

Just recently, you have accompanied me on my search for the ultimate method 

for cutting/forming of polycrystalline diamonds (see part 7 – hp tooling, 2023, 

#4). We succeeded. The “spirit in a bottle” was able to escape as a tiny little 

spark. On the same day, only hours later the patent was registered. 

A new and exciting era of the industrial use of diamonds began; thanks 

to the durability of diamonds, the now possible serial production of tools, 

and due to the use of robots in the automotive and supply industries, wood 

and furniture industry, airplane, wind energy and composite industries and 

thanks to many other factors. Aluminum and materials like glass and carbon 

fibers, all difficult to process, were now under control; electro-graphite 

carbon and, for example, ceramic and carbide in its green state could now 

be processed much more efficiently. It was like looking into a black hole, 

while gaining new and surprising insights and finding new solutions on a 

daily basis. 

LACH-EDGplus® (Electrical Discharge 

Grinding) process for spark grinding of polycrystalline 

cutting materials, PCD and PCBn 

European Patent No. 0 010 276 

Method and device for electroerosive machining synthetic polycrystalline 

diamond and use of the diamonds machined according to this method. 

Priority: October 13, 1978 – granted and published April 21, 1982 

Patent claims (excerpt): 

1. Method for electroerosive machining synthetic polycrystalline diamond, 

characterized in that for producing arbitrary profiles the machining is made 

by means of spark erosion. 

2. Polycrystalline synthetic diamond produced according to claim 1, 

characterized in that the synthetic polycrystalline diamond machined by 

spark erosion shows the profile of a circular disc or a circle section or a 

circular ring or a circular ring section or a rectangle or an ellipsis section or 

of a form composed of these configurations. 

3. Use of synthetic polycrystalline diamonds machined by spark erosion as 

cutting edges in single or multiple-cut rotary tools, preferably for machining 

of hardwood or synthetic resin sheets or particle boards. 

Diagram of spark erosion grinding with 

rotating electrode, either graphite or copper 


news & facts 

Application examples – 

250-350 times superior durability compared to carbide 

While I am writing this, November 2023, I begin to ponder. 

Dreams of the future? An article in the german magazine 

“Der Spiegel” (no. 39) on the “Magic of ice clouds” which lead 

to diamond rain on the planet Neptune surprises me. On 

earth the so-far largest diamond found weighed only 600 g, 

equal to 3,000 carat (1 g = 5 carat). Scientists are already specu - 

lating that diamond blocks measuring several meters, if not 

kilometers, could exist in the inside of the icy giant Neptune. 

A task for the year 2088 when the first returning space robots 

present diamond blocks to us. A task for our little spark? 

Well, we still have to discuss the years after 1979 which, have 

been and will continue to be exciting. 

The stuff that dreams are made off 

The first results from polycrystalline diamond-tipped profile 

cutters, made for the company Resopal, for use on double- 

end profilers, were – for us (me), and for the crew of Resopal – 

something like the stuff that dreams are made off. Little by 

little we realized that we had made a momentous discovery. 

The tool life of diamond tools, produced with the help of the 

“little spark,” had levelled off at 250 to 350 times that of the 

previously used traditional carbide tools. 

Until then the technicians/foremen already had to change 

carbide tools after one shift, and for that reason they had to be 

present through the third shift – they were more than happy 

about the extended durability of diamond tools. 

At the start of January 1979, during my initial phase of 

euphoria, I asked my father how we should proceed with 

this development. I will never forget his answer: “I am now 

85 years old, if you want to do this, you are welcome to”. 

PCD diamond profile milling tool on 

double-ended profiler (unilateral view), 1979 

Diamond milling tools cutting wood 

and plastic materials 


27

news & facts 

After examination, a diamond profile 

milling cutter was marked “BG-Form” 

back then – today “BG-Test” 

The first certified 

dia profile milling cutters 

according to “BG-Test” 

dreboquick® – a good idea, 

unfortunately not feasible; it failed due to 

imprecise fittings for the inserts 

This signaled the start for the foundation of the company 

LACH-SPEZIAL-WERKZEUGE (LACH Special Tools), 

established as Ltd. in February 13 th , 1979, at my friend 

Gerhard Grossmann’s notary’s office in Frankfurt. 

Do it 

Even in retrospect, at that time it was a good recommendation 

of my father to separate the new company 

“LACH-SPEZIAL” from the existing LACH DIAMANT 

company, which was more closely connected to the metalworking 

industry, with the goal to win customers in the 

wood and plastics industry. Luck was an additional factor, 

since the AiF (German Federation of Industrial Research 

Associations) had just started an aide programe for small 

and medium-sized start-up companies, and they had established 

company-specific assistance measures. The project 

“Diamonds cut wood and plastic”, launched upon the foundation 

of LACH-SPEZIAL, could take off. 

We hired employees, purchased the first machines – one 

of them a wire EDM machine – and our R&D work as well 

as our search for new customers could begin. The question 

being, who needs LACH-SPEZIAL tools for all wooden 

materials? 

In short and simply put, you could answer this question 

today with: “Look it up on the internet”. However back 

then, 1979, we did have publications like “Who supplies 

what”, “ABC of the german economy” and also tradeshows 

with a special focus on wood as raw material. One example: 

LIGNA, an international trade fair for woodworking and 

wood processing. 

The world’s first presentation of diamond tools for 

plastic and wood machining at LIGNA 1979 in Hanover 


news & facts 

Another way how diamond tools for wood and 

plastic machining were presented at LIGNA 1979 

One of the first dreborid® D profile steels for 

aluminum processing, produced with the “little spark” 

So LIGNA 1979 in Hanover was selected for the first 

presentation of “Diamonds for all wood materials” by 

LACH-SPEZIAL-WERKZEUGE GMBH. It was a good thing 

that LACH DIAMANT had already booked a large peninsula 

booth there. Now, the “cat was out of the bag” – the 

secret of our LACH specialists, so long kept behind closed 

doors, was finally out. 

To the surprise of all, especially the suspiciously observing 

manufacturers of woodworking tools at that time, the team 

of the first hour had succeeded in presenting a complete portfolio 

of diamond tools, analog to the available carbide tools 

for milling, scoring, cutting, and sawing etc. 

The idea to fit commercial, exchangeable carbide inserts for 

milling cutters with diamonds had to be discarded. First attempts 

with dreboquick® PCD inserts, custom-made for this 

project, quickly brought to mind the abrasiveness and durability 

of our chosen diamond cutting material! The tolerances 

of the available milling cutters were so variable and large 

that the installed dreboquick® cutting inserts would create 

unclean milling marks which would not equalise, even after 

extended use, like carbide; typical for diamond! 

This insight led to a problem for the new production. No 

removable inserts for the wood-milling cutters meant soldering! 

Apart from the diamond-depreciating statement “Lach 

has gone insane – now he wants to cut wood with diamonds”, 

now rumors were spread that the diamonds soldered onto 

milling bodies were “dangerous for life and limb” because 

they would get loose at high speeds. Well, even this claim did 

not impede the triumphant success of diamond for all wood 

materials and of course for aluminum etc. also. As a side 

note: these soldered milling cutters were the forerunners of 

the “Monoblock” milling cutters later used in metal working. 

A triumphant success begins 

Customers invited to the LIGNA exhibition booth, and first 

diamond tool users were so enthusiastic that trade press 

reporters, present at the event, announced a “Diamond era”. 

Space for LACH-SPEZIAL at LACH DIAMANT’s facilities 

became increasingly cramped. Jakob Lach, now 85 years old, 

still followed the developments with great interest and pride, 

and he knew what to do. A locksmith’s shop, not far from 

our headquarters at Bruchköbeler Landstrasse in Hanau, 

Germany, and space at the already transferred production facility 

for diamond and CBN grinding wheels were available 

for a move in August. 

Only a few weeks afterwards, September 1 st , 1979, three 

employees started work at – what was now called – “LACH 

Group”. During the following years they would make 

their impact on LACH DIAMANT and LACH-SPEZIAL: 

Edgar Schneider, later the product manager for diamond 

dressing tools and electroplating of diamond and CBN abrasives, 

Horst Köllner (✝) as grinding specialist and application 

technician, and for LACH-SPEZIAL Dieter Claus, a former 

helicopter mechanic, who would later dedicate his special 

talents to development, application, and sales of diamonds 

for cutting wood and plastics. 

It was time to add new employees to the young 

LACH-SPEZIAL team in order to accelerate their success, 

such as Achim Weber, later facility manager, and freshlyhired 

Günther Pallischeck and Heinz Katta, with the result 

that diamond tools became indispensable for the wood and 

furniture industry. 

Many new ideas, also outside of the prevailing school of 

thoughts, were now implemented and introduced to different 

industries. In the meantime, independent of the developments 

at LACH-SPEZIAL, the “little spark” had also gained 

importance at LACH DIAMANT. Wire EDM machines were 

used as well as sinking machines with profile electrodes. 

And now machines 

Speaking of electrodes for sinking EDM machines; a former 

employee, Gerhard Mai, recently reminded me how, at that 

time, I had once observed this machining process in detail; 

the copper electrode had to be polished after each use, 


29

news & facts 

which was especially time-consuming for profiled electrodes. Apparently, 

after studying the process, I suddenly said: “What if we could bend this electrode 

round?” This was basically the invention of “spark grinding” with profiled, 

rotating graphite or copper wheels, also known as “EDG grinding 

process (electrical discharge grinding), and its neologism “EDG-plus” is 

today one of our protected trademarks. I had completely forgotten about 

this; I should have filed a patent application… 

“But not to worry, Horst Lach” – since this was the start of machine building 

for LACH DIAMANT at the same time. First for our own use, and later 

also for sale to service grinding shops and other diamond tool manufactures. 

Until today CNC-controlled EDG-plus rotation grinding machines for 

“contactless” grinding of polycrystalline diamond tools and saws, drills, and 

other similar tools, are manufactured and sold worldwide. 

A report in hp tooling, 2021, #4 (“Poly, poly or what? 10 th part – When sparks 

learned to fly on diamonds”) gives an account of the development of versatile 

new models and applications. Today our top model is the “Dia-2200-mini” 

for ultimate service and manu facturing of diamond tools and saws. 

Advancing development 

If I may say so, the size of polycrystalline diamonds kept up with the 

expansive development of the LACH group. During LIGNA times the 

available PCD inserts had just about 0 8.1 mm then; but only a few months 

later already 0 13.2 mm. Through continual contact to the manufacturer 

General Electric, and here especially to Louis Kapernaros (✝), who was welldisposed 

to our efforts, I tried to advance the development. You can easily 

imagine how manufacturers of PCD tools had to do without the “little spark” 

until 1978, and for that reason only tools with soldered-on diamonds were 

available, as for example turning tools. With the now possible variety of 

milling tools and saws, more and more diamonds per piece were needed. A 

chance for GE to invest in presses and therefore larger PCD inserts – meaning 

for LACH better purchase prices, and therefore greater efficiency for our 

customers. 

Dia-2200-mini, universal CNC spark grinding machine for 

diamond milling cutters, hoggers and saws up to 0 600 mm 

First beginnings of LACH SPEZIAL production, 

under management of Achim Weber (photo) 

and Dieter Claus 

Among the many events of the years 1979/80 

one stands out. Around February 1980, Dieter 

Claus appeared in my office, apparently very 

excited. “There are two gentle men out there 

who want to build a special machine for machining 

circuit boards – what should I tell 

them?” I reminded him of an old catalogue 

from 1976/77, featuring images of simple 

PCD milling tools and the like, and our collective 

experiences during productronica 

1977. The result being that both gentlemen 

were enthusiastic about the possibility, thanks 

to the little spark, to now use PCD efficiently 

for machining circuit board materials such 

as fiberglass boards. By the way, the visitors 

were Mr. Löhr and Mr. Herrmann who later, 

very successfully, built a machine of the same 

name based on their concept of “multi-layer 

machining”. Thereby PCD had conquered a 

new industry, a new sector: machining of circuit 

boards. 

The story will continue, even internationally, 

in our next 100-year anniversary article. 

Yours, Horst Lach 

further information: www.lach-diamond.com 


processes 

Extreme surface finish for e-mobility 

Particular precision and process reliability have 

characterized automotive engineering for many decades. 

With the establishment of e-mobility, however, these 

demands are increasing once again, because many 

e-motor components need to be manufactured even 

more “perfectly”. In most cases this involves the highest 

surface finish in the micrometer range so that no 

loud running noises occur on the gear components. In 

a quiet e-motor, for example, these noises would be 

audible. In this context, the technology of EMAG SU 

is drawing the attention of many production planners. 

Among other things, the specialists developed high-performance 

solutions for gear grinding – including short chip-tochip 

times, intelligent axis concepts, thermal and mechanical 

stability and a high degree of user-friendliness. Which 

machines and processes are the focus here? 

Outstanding solutions for the field of gear profile grinding 

include the G 250 machine on the one hand and the G 160 

on the other. The G 160 is used for components up to module 

three and with a maximum O/D (outer diameter) of 160 mm. 

In this field of application it is the fastest machine on the 

market, made possible by two parallel workpiece tables that 

move alternately at high speed to the grinding wheel. Thus, 

while one component is machined, the internal loading robot 

inserts a blank into the other spindle or unloads the beforehand 

finished component. Additionally the axis concept 

ensures perfect surfaces, which are so important in e-mobility. 

The decisive factor here is that the G 160 does not have a 

tangential axis, but instead the existing Y- and Z-axes generate 

a “virtual” tangential axis through simultaneous movement. 

As a result the distance between the A-axis and the 

tool contact point is very small, which in turn prevents the 

so-called “ghost frequencies” on the surface of the component. 

The possibilities this approach opens up for e-mobility 

are shown by the example of an “intermediate shaft” with 

21 teeth and a normal module, where a floor-to-floor time 

of only 33 s (including entanglement compensation and proportional 

dressing time) and a grinding time of only 25 s are 

achieved. Similar performance values are shown for an input 

shaft with 26 teeth and a module of 1.6 mm. Here the pure 

grinding time is only 28 s. 

Minimum floor-to-floor times 

The larger G 250 machine also scores with precision, minimum 

chip-to-chip times, short setup times and reliability 

for components with a maximum length of 550 mm. The 

machine has also a double table (like the G 160). Loading and 

unloading operations as well as component measurement 

are thus performed in cycle time-concurrently. Additionally 

the grinding mandrel can accommodate grinding wheels 

with different diameters, and the entire design is very rigid. 

Gear generating grinding and profile grinding take place on 

the main grinding spindle, so the machine does not have a 

thermal growth. It can also be retooled for the other process 

in just a few minutes. In the field of e-mobility, for example, 

The G 250 (like the G 160) also has a double table, 

loading, unloading and measuring of the 

components thus takes place in 

cycle time-concurrent 

this approach is used for grinding axle drive wheels. The 

floor-to-floor time here is only 69 s (including entanglement 

compensation and proportional dressing time), with the 

actual grinding time comprising only 58 s. The G 250 

achieves a comparably high productivity level when machining 

pinions with a strong crowning in the tooth flank profile 

and normal crowning in the flank line. The bottom-to-bottom 

time is 33 and the grinding-only time is 28 s. A DIN 3962 

quality of 4 is achieved. 

Sky-Grind: signigicantly lower costs 

Furthermore EMAG SU illustrates what the general future 

of gear grinding could look like with the establishment of 

the new “Sky-Grind” process. Here the final grinding on 

the gear is carried out completely dry – with great financial 

advantages for the users, because the filter system, cooler 

and co. (which are normally required for wet grinding) are 

no longer needed, thus reducing the initial investment. In addition, 

energy consumption is massively reduced. The whole 

thing is made possible by a dual-tool system with two different 

tool spindles in the machine: one for finish-machining by 

hobbing and one for finish-machining by grinding. In practice, 

this means that, in the case of the classic automotive 

gearwheel with 100 µm allowance per flank, the Sky-Grindprocess 

removes 90 µm by hobbing and only 10 µm by gear 

generating grinding. In the end, the cycle times of conventional 

wet gear grinding and the Sky-Grind process are very 

similar; however, the costs are very different. 

How can EMAG SU’s know-how and offers be summarized? 

“You could certainly say that we guarantee our customers 

competitive advantages and a fast return in investment,” 

answers Alexander Morhard from EMAG SU. “To this 

end we continuously invest in research and development to 

further increase the efficiency and environmental friendliness 

of the machines. The result is perfect solutions for the 

production of ultra-fine surfaces with different contours.” 

further information: www.emag.com 


31

processes 

High-end surfaces of gears for electromobility 

written by 

Janis Thalau and Dr.-Ing. Philip Geilert, 

technology testing/fundamentals, KAPP NILES GmbH & Co. KG 

Introduction 

While the quantity of gears within drive trains for e-mobility has drastically 

decreased compared to drive trains for vehicles with combustion engines, 

their design has changed significantly and alongside the geometrical tolerances 

were massively sharpened. The reasons for this are twofold: with the 

omission of the noise emission of the motor, the gear boxes acoustic behavior 

moved into focus. Furthermore the range of electric vehicles became an important 

selling argument, which is why the transmission efficiency of drive 

trains gained in importance considerably. 

New requirements and challenges 

There are a number of changes in requirements with regard to the drive components 

of electric vehicles: 

• Reduction of noise emissions 

Due to the elimination of masking noise from an internal combustion 

engine, noise emissions from the transmission can dominate in the 

low speed range. 

• Higher loads 

The gears in the transmission of electric vehicles are under different 

and potentially higher loads, as they generally only have one gear (and 

two gear stages). In addition electric motors have a different speed/ 

torque curve (already high torques at low speeds). 

• Higher efficiency 

The efficiency of an electric motor is significantly higher than that of 

an internal combustion engine. This contributes to the great relevance 

of the transmission’s efficiency. 

• Complex contact mechanisms 

In order to meet the above-mentioned requirements, the different 

mechanisms occurring during the gear tooth contact within the 

transmission must be considered. These include the material fatigue, 

excitation and tribological behaviour of the gear pair. These contact 

mechanisms are influenced by the shape deviations of different orders 

(1 st order: form deviation, 2 nd order: waviness, 

3 rd & 4t h order: roughness, 5 th order: microstructure). 

• Lightweight construction 

In order to be able to map the high speed 

ranges of transmissions for e-mobility 

drive trains, lightweight construction 

of gears becomes more common. 

This results in challenges with regard 

to heat treatment related distortions 

as well as workpiece clamping. 

• New measuring values 

In roughness measurement, “new” 

characteristic values are increasingly 

being used, some of which are only 

defined by factory standards. 

Achievable quality by 

different finishing technologies 

The consequent increase in demand for 

smoother surfaces on tooth flanks leads to 

a wider use of surface finishing technologies 

such as fine grinding or polish grinding. 

While surfaces manufactured by fine grinding 

still exhibit a structure comparable to conventionally 

ground surfaces but with a much 

lower amplitude, polish ground surfaces almost 

entirely lack roughness peaks. 

New requirements and challenges regarding gear grinding for EVs 

Factors influencing the optimisation strategies 


processes 

Grinding of an e-mobility shaft with a combined grinding worm 

Waviness analysis on a KNM 2X measuring machine 

Challenges of polish grinding technology 

The distinctive structure of polish ground surfaces is caused 

by the elastic nature of the often used polyurethane-bound 

grinding tools. While the structure of the surfaces manufactured 

with these tools seems to be preferable in comparison 

to fine grinding, the elastic behavior of the tools poses great 

challenges for meeting the tighter tolerances regarding form 

deviations. Geometrical effects such as dents, rounding of the 

tooth tip, constrictions around the tooth root or waviness are 

typical for polish grinding. 

Adapting the polishing pressure can improve the surface 

quality and reduce geometric anomalies. While a reduction 

of the center distance between tool and workpiece leads to 

a global increase in polishing pressure, it is often necessary 

to modify the polishing pressure in a local manner to avoid 

the mentioned geometric anomalies. Furthermore the quality 

of the ground tooth flanks, which represents the initial 

condition of the polishing process, must never be left unconsidered 

in the design of the polish grinding process or when 

analysing geometric deviations. 

Challenges of measurement technology 

Achieving new levels of surface quality while also meeting 

the requirements regarding form deviations does not only 

challenge manufacturing technology but is also demanding 

in regard to measurement technology. In this context, conventional 

values for describing surface roughness such as 

Ra and Rz as well as form deviations such as ffα and ffβ lose 

their significance. Therefore, values derived from the Abbott- 

Firestone curve for surface description and waviness analyses 

come to the fore when characterizing the quality of gearboxes 

for electromobility. 

Optimization strategies by KAPP NILES 

In the past years KAPP NILES has developed several strategies 

as to how machine, software, tool and process design 

must be adapted to reach an optimal balance between productivity, 

surface quality as well as form deviations. In this 

context, e. g. dressing tool design as well as dressing technology, 

new correction options within the machine software or 

optimization of the dynamic behavior of machines as well as 

drives and axes can contribute to fulfill the ambitious quality 

requirements for gears in e-mobility. 

Janis Thalau 

technology testing/ 

fundamentals 

Process design for 

polish grinding 

Dr.-Ing. Philip Geilert 

technology testing / 

fundamentals 

further information: www.kapp-niles.com 


33

processes 

Benefit from tried-and-tested grinding technology 

Contract manufacturers in particular must be able 

in trusting completely in the technologies, machines, 

and processes they use. Only then can they manufacture 

one-off and small-batch components with extreme 

precision and process reliability. That’s why 

Ingold Tools AG, a well-known precision manufacturer, 

relies on CNC cylindrical grinding machines from 

STUDER. 

Christoph Jenzer, managing director at Ingold Tools in 

Inkwil, proudly states that his production specialists have 

had excellent experiences with STUDER cylindrical grinding 

machines for many years. “Even on an old grinding machine 

that has a belt drive and is close to being an antique 

itself, our experts were able to achieve exceptional roundness 

accuracy and superior surface quality on the machined 

workpieces. The outstanding quality of STUDER’s grinding 

machines has continuously impressed me for many years.” 

As Christoph Jenzer puts a high premium on reliable technology, 

he consistently invests in tried-and-tested grinding machines. 

“As in the past, the quality of a grinding machine continues 

to be determined by whether it has a stable and fully 

settled platform. That’s why, up to now, we have exclusively 

procured grinding machines that have already proven themselves 

over several years. Naturally this is very advantageous 

from an economic perspective,” he explains. After annual 

investments starting in 2014, the manufacturing facility in 

Inkwil now boasts eight STUDER CNC cylindrical grinding 

machines. 

Reliably leak-tight: using an S21 cylindrical grinding machine 

retrofitted with a motor spindle for internal and thread 

grinding, Ingold Tools accurately machine bores and 

control slots in valve housings with a precision 

of 2 μm (0.000,080 '') 

Reliably leak-tight: 

After control pistons 

have been milled, 

drilled, pre-turned 

and coated with hard 

plastic, they undergo 

precise grinding on a 

STUDER cylindrical 

grinding machine to 

achieve a diameter 

accuracy of 2 μm 

(0.000,080 '') 

Comprehensive range clinched the deal 

Christoph Jenzer’s preference for cylindrical grinding machines 

from Thun-based STUDER is also rooted in the large 

variety offered by this manufacturer. “At STUDER, we always 

find the machine needed for our comprehensive range of 

components,” he says. For example the contract manufacturer 

now machine workpieces ranging from 0 around 10 mm to 

450 mm (0.4 to 17.7 '') and 1,6 mm (63 '') in length on STUDER 

machines like the S21, S31, S33, S40 and S41. First the manufacturer 

had all the machines overhauled by the overhauling 

department of STUDER. On some of them, additional machining 

capabilities were added. This was the case, for example, 

with an S21 cylindrical grinding machine on which 

internal and thread grinding as well as in-process gauging 

for adaptive grinding had been added. As Christoph Jenzer 

emphasizes, the manufacturer always provided comprehensive 

support for the overhauls, with qualified service and 

readily available spare parts. Claudio Delmenico, area sales 

manager at STUDER, adds: “Even with grinding machines 

tried and tested over many years, we ensure that manu - 

facturing companies can benefit from the advantages of our 

technology. This includes consulting, service, technical information 

and spare parts, not only for the mechanical systems 

and drive technology we developed but also for the control 

technology and software.” Christoph Jenzer confirms the service 

personnel at STUDER being highly responsive and dependable. 

One always has prompt access to competent contact 

persons and qualified information, enabling reliable 

grinding even on tried-and-tested machines. 

Accurate to the micron 

The manufacturing engineers at Ingold Tools achieve exceptional 

precision by combining their know-how, acquired 

over many years, with the tried-and-trusted CNC grinding 

machines. As an example, Christoph Jenzer cites bearing 

covers for motor spindles used in high-speed machining. 

At Ingold Tools they first undergo turning and milling 


processes 

Complete machining: through turning and milling operations 

and a final grinding process, Ingold Tools carries out the 

complete production of bearing covers for motor spindles 

used in high-speed machining 

Christoph Jenzer (Ingold Tools) chats with Claudio Delmenico 

(area sales manager at STUDER) left to right; 

Ingold Tools benefits from the outstanding characteristics 

of proven STUDER cylindrical grinding machines 

operations, followed by cylindrical grinding on the external 

and internal diameters, with a precision of up to 2 μm 

(0.000,080 '') in the position form, and dimensional accuracy. 

Christoph Jenzer explains: “In grinding, the pre-machining 

also determines whether the desired and required accuracy 

can be achieved. Therefore we prefer to machine difficult 

and complex components in-house, from the blank to 

the high recision finished workpiece. With this we of course 

position ourselves as competent partners for precision manufacturing 

for our customers.” On select components the specialists 

in Inkwil are even able to achieve a high polish finish 

through a process called lap grinding. Thanks to this 

outstanding performance, Ingold Tools AG has established 

a strong presence in multiple industries, including drive 

technology, machinery and special-purpose machines, hydraulics 

and clamping technology. For the latter mentioned, 

Known for precision 

Founded in 1946 as a supplier to the machine tool industry, 

Ingold Tools AG initially produced mainly punching tools, 

gauges, jigs, injection nozzles, and special bearings and 

machine components. Osterwalder AG in Lyss acquired the 

company 1974, transformed it into a stock corporation, and 

operated it as an independent subsidiary until 1992. Then 

Ingold Tools AG became an independent company again and 

currently has about 30 experienced and highly qualified 

employees. The range of services includes turning, milling, 

drilling, internal and external cylindrical grinding, surface 

grinding, honing lapping, assembly of components, 

sandblasting and polishing, as well as laser engraving. On stateof-the-art 

machines, such as fully automated multi-axis turning 

and milling centers, the company manufactures complex 

custom components from steel, non-ferrous and light metals 

and plastics. All components are produced with high precision, 

flexibility and short lead times, based on individual drawings 

and 3D data. The company is certified in accordance to ISO 

9001 and 14001. Components can be reconstructed from 

samples by creating 3D data for manufacturing them 

on request. Subcontractors handle heat treatments and 

surface coatings as partners. 

Ingold Tools, for example, produces standardized and customized 

jaws for a wide range of mechanically and hydraulically 

actuated chucks from numerous manufacturers. As an 

example of a particularly demanding machining process that 

he and his skilled staff executed easily, Christoph Jenzer 

presents a control piston coated with hard plastic. “To 

achieve a diameter and form accuracy of approximately 2 μm 

(0.000,080 ''), we first milled and drilled the pre-turned blank, 

had it coated with hard plastic at a partner company and subsequently 

ground the external and internal diameters on our 

tried-and-tested CNC grinding machines.” 

Expanding capacities 

To strengthen his good reputation in the industry and expand 

his precision machining capacities, Christoph Jenzer 

invested further in a CNC cylindrical grinding machine 

from STUDER. A tried-and-tested overhauled S41 universal 

cylindrical grinding machine with a swiveling wheelhead 

and four usable grinding spindle ends. “This machine 

enables us to reduce our lead times and increase our flexibility. 

On it we can grind components to completion in a single 

clamping operation,” explains Christoph Jenzer regarding 

his investment. He now considers it almost naturally that 

he can count on the support of the service technicians any 

time, just as he has done seven times in the past. “So far, our 

experience has been very good. Therefore we will continue 

to cooperate with STUDER. For a contract manufacturer who 

needs to operate productively and economically at all times 

and cannot tolerate machine downtime, the machines from 

STUDER have proven to be ideal,” adds Christoph Jenzer. 

Furthermore, the specialists at Ingold Tools are thoroughly 

familiar with the programming and operating interfaces of 

these CNC grinding machines. This is another advantage. 

The machine operators can effortlessly alternate between 

several machines. “Why would I bring in another manufacturer 

with an unfamiliar concept?” Christoph Jenzer 

asks rhetorically. Because of this he is already planning to 

purchase a ninth machine. 

further information: www.studer.com 


35

processes 

Complete solution for grinding and eroding 

The VHybrid 260 sharpening machine from 

VOLLMER offers a complete solution for grinding and 

eroding. Alexander Schmid explains why it is the epitome 

of flexibility and precision. Alexander Schmid is 

product manager for rotary and PCD tools and the 

person to contact at VOLLMER when it comes to the 

VHybrid combined grinding and erosion machine. 

Mr Schmid, the name says it all with the VHybrid 260 

grinding and erosion machine, but what exactly does 

“hybrid” mean? 

Alexander Schmid: the word “hybrid” is of Greek origin 

and describes something crossed or mixed. In term of 

technology, the VHybrid 260 combines the best of both 

worlds – “grinding” and “eroding”. Our erosion machines 

sharpen tools with PCD (polycrystalline diamond) using 

non-contact spark erosion. The concept of the VHybrid 

is based on that of our VGrind tool grinding machine, 

which enables multi-level machining using two vertically 

configured spindles. With the VHybrid the upper spindle 

is used purely as a grinding spindle, while the lower spindle 

can both erode and grind. 

What tool manufacturers are interested in a 

combined grinding and erosion machine? 

Alexander Schmid: all tool manufacturers who aim for 

a high degree of variability in tool manufacture. Our 

VHybrid is the ultimate in flexibility, allowing companies 

to adapt their tool manufacture to current demand any time. 

Regardless of whether carbide or diamond tools are required, 

the VHybrid offers a complete solution for both sharpening 

processes in a single machine. In addition the global market 

for tools shows that the use of complex tools such as fullhead 

PCD tools is steadily increasing. A combined machining 

process, consisting of erosion and grinding in a single 

set-up, is essential in order to produce these tools 

precisely and cost efficient. 

Isn’t a machine with two technologies more 

complicated to operate? 

Alexander Schmid: as far as the operation of the VHybrid 

is concerned, we at VOLLMER rely on our proven concept, 

which is based on intuitive operation with familiar software 

solutions. All machines customers can get are operated in 

the same way. 

You have incorporated simple operation and flexible use 

into the VHybrid; what technology is behind these 

advantages? 

Alexander Schmid: at the core of the VHybrid is our Vpulse 

EDM erosion generator, which we developed in our Research 

Alexander Schmid 

development. We are constantly working on making the 

generator more efficient. It currently achieves a surface 

quality of 0.05 μ Ra, which is equal to one thousand th of a 

hair’s breadth. Nevertheless we have customers who are 

less concerned with surface quality and want maximum 

machining speed instead. With the VPulse EDM erosion 

generator, a user can choose between maximum efficiency 

or the highest surface quality. With this option, a tool 

manufacturer can always adapt the sharpening process 

to its needs. What’s more, software-based V@ boost 

performance packages can improve the performance of 

the VHybrid by up to 35 %. Customers can activate the 

software package by the hour or purchase it permanently. 

Which industries or markets do you want to reach 

with the VHybrid 260? 

Alexander Schmid: From a market perspective, the global 

manufacturing industry worldwide now mainly requires 

PCD tools with less than 0 150 mm. Our VHybrid 260 is 

able to produce these types of tools, which then go on to 

be used throughout the woodworking and metalworking 

industries. At EMO 2023 we demonstrated for the first time 

how tool manufacturers can produce even the smallest 

microtools with 0 of 0.45 mm and below with the highest 

precision, performance and surface quality thanks to the 

optimized generator. PCD microtools with 0 of 0.45 mm 

and below are in particularly in demand for the production 

of microchips. Sectors such as the electronics industry or 

medical technology, which require ever smaller electronic 

components for increasingly compact implants and 

wearables, are benefiting from this in particular. 

further information: www.vollmer-group.com 


processes 

Automated cutting edge optimization of 

stamping and forming tools 

The challenge facing the OTEC team of experts was to find an 

automated solution that delivers consistently high-precision results 

for the stamping and forming machines of the renowned machine 

manufacturer Bihler. Optimum cutting edge rounding and a 

high-gloss polish on surfaces of the most varied tools made of hard 

metal or hardened steel are achieved in just one step using the OTEC 

machines. This ensures the long service life of tools and signifi cantly 

reduces production costs. 

Consistent high performance quality with measurable success 

For the tool industry, achieving the best possible product quality and increasing 

efficiency in the manufacture of stamping and bending parts are 

crucial for maintaining a competitive edge in the market. For the success 

story of Otto Bihler Maschinenfabrik, in particular, this means optimal cutting 

edge rounding of 10-20 μm and a high-gloss polish on the outer surfaces 

with a surface roughness of up to Ra 0.02 μm for cutting punches and dies. 

This high performance quality means that even with a higher cycle time, 

the hard metal or hardened steel tools achieve consistently and reliably precise 

results and a maximum service life. Using the latest 3D measuring technology 

from Keyence the quality is also constantly and reliably checked and 

documented. 

Precise process flexibility using an 

automated Stream Finishing solution 

A customized process designed to fully meet the exacting surface requirements 

was developed in the OTEC Finishing Center. The requested roughness 

parameters for the stamping and forming tools were achieved by using 

mass finishing technology, what is called the Stream Finishing process. 

With the SF technology workpieces are clamped in a holder and lowered 

into a rotating container filled with an abrasive or polishing medium. The 

granulate-type abrasive circulates around the workpieces, thereby ensuring 

even, homogeneous abrasion. By adjusting the processing parameters and 

the type of abrasive used, both highly abrasive and fine polishing processes 

can be performed with just one machine. 

A special cycle mode in the machine means that this process is also suitable 

for the most varied tool geometries. The angle of the clamped tool is repeatedly 

changed automatically during the process so that the most varied 

surfaces can be specifically targeted. Thanks to the optimized processing of 

the tools in the Stream Finishing unit, manual process steps (tasks) are no 

longer required. The innovative solution is reliable and delivers consistent 

results without fluctuations. 

Hand-in-hand: implementation of the process for the customer 

The successful interaction between machine size and equipment, abrasive 

and the correct process parameters was determined as a process using tools 

used in series production by the customer and then tested in real use. Following 

installation of the OTEC SF-1 with intermittent drive, the unit was 

successfully commissioned at Bihler with the help of the OTEC specialists. 

Continued support from Process Development and After-Sales will guarantee 

excellent process reliability and efficient use of the unit on a long-term 

basis. 

Benefits of OTEC surface processing 

• surface roughness parameters 

are significantly reduced 

• flexible processes for the most 

varied requirements for tools 

• fast processing 

• no fluctuations in quality as a 

result of automation 

• durable high-quality products and 

increased productivity hines 

The surface is now the top performer 

The use of the OTEC Stream Finishing units 

leads to effective resource and cost savings 

while at the same time achieving the required 

surface roughness parameters and surface 

properties. The extremely high demands of 

hard metal tools in terms of consistently high 

product quality and increased effectiveness 

in production are reliably met and the service 

life of the parts is increased significantly 

while at the same time reducing maintenance 

costs. 

The special property of the mass finished 

surface topography with its significant reduction 

in roughness peaks allows excellent performance 

of the tools. Smoothing and polishing 

of the surfaces reduces friction and thus 

the thermal load. This significantly reduces 

wear on the tools and prepares the surface 

perfectly for a coating. 

further information: www.otec.de 


37


Swiss quality as a price leader 

STUDER is internationally renowned for its high-end cylindrical 

grinding machines, but even with its entry-level machines, cus tomers 

benefit from uncompromising quality and precision. 

“We are continuously expanding our entry-level range for customers who 

appreciate STUDER quality and utmost precision but do not need all 

the features from the premium segment,” says Sandro Bottazzo, CSO of 

Fritz Studer AG. He describes the philosophy behind the entry-level 

machines in the product range as “uncompromising STUDER quality and 

precision at an entry-level price.” Specifically the machines in the entry-level 

segment include the favorit, favoritCNC and S100 models. 

But what exactly is an entry-level machine? “Compared to our high-end 

models, the number of tools and range of spindle power is limited, and many 

technical processes and interfaces standardized – this allows them to cover 

a wide range of grinding applications with excellent value for money,” says 

Daniel Huber, CTO of STUDER. Depending on the model, optional accessories 

and adaptations are also possible, allowing companies to make their 

specific production even more efficient. STUDER thus has the right machine 

for every area of application. “Our sales staff and representatives are familiar 

with the specifications of each machine and can accordingly offer the suitable 

model with the optimal configuration”, adds Bottazzo. 

The best of both worlds 

Customers get the best of both worlds: they benefit from an economical price 

while receiving an uncompromisingly high-quality product with the globally 

recognized STUDER performance, utmost reliability and maximum precision. 

Another unique feature that all STUDER entry-level machines have 

in common is very short delivery times. This is possible thanks to the company’s 

in-house manufacturing concept and flow assembly+ (plus). Here 

STUDER’s experts assemble the machines on a specially designed, highprecision 

conveyor system. Customers benefit from the shortest throughput 

times and high manufacturing quality. 

Okyay Erik, general manager of the Turkish automotive supplier Celikis, 

describes what this means for customers in practice: “We were surprised by 

what the STUDER favorit can achieve, even though it’s classified as an entrylevel 

machine.” The company based in Izmir 

produces various products including differential 

gears, shafts and housings for major 

automobile manufacturers. “With the favorit 

we have significantly increased the efficiency 

of our driveshaft production,” reports Erik. 

“Where we used to produce 15 drive shafts per 

hour, we now manage 25 in the same amount 

of time. Plus, we no longer need to use a measuring 

system, as the machine’s accuracy is 

very high. This in turn reduces reset times, 

significantly boosting productivity.” 

Entry-level machines can handle 

key applications 

As a CNC universal cylindrical grinding machine 

that is easy to program thanks to the 24" 

multitouch screen, the favorit can grind both 

short and long workpieces weighing up to 

150 kg (330 lbs) – in single or series production. 

The cross and longitudinal slides, made of 

high-quality gray cast iron, ensure the highest 

precision. As all STUDER machines, the machine 

bed is made of the patented mineral 

casting Granitan®, which ensures the best surface 

quality of the ground parts with its excellent 

damping and thermal behavior. These are 

just a few examples of how customers benefit 

from STUDER’s premium manufacturer 

status even in entry-level machines. 

The same applies to the favoritCNC. This 

CNC universal cylindrical grinding machine 

is the leader in terms of value for money and 

can be adapted to a variety of grinding tasks 

with different options such as a measuring 

system, balancing system, contact detection, 

and longitudinal positioning. With a distance 

between centers of 650 mm (25.6") or 

1000 mm (39.4"), it is universal usable and can 

handle key applications. Its high grinding precision, 

even at this entry-class level, is demonstrated 

by its high roundness accuracy of less 

than 0.0004 mm (0.000,016"). And thanks to 

the in-house StuderPictogramming grinding 

software even complex grinding cycles can 

be executed easily and intuitively. 

The CNC universal 

internal cylindrical grinding machine S100 

Ease of use is particularly important 

With the S100 there is also a specialist for 

internal cylindrical grinding in the entrylevel 

portfolio, serving as the counterpart to 

the favoritCNC in external cylindrical grinding. 

It handles a wide range of internal, face, 



The CNC 

universal cylindrical grinding machine favoritCNC 

and external grinding applications with the highest accuracy and is thus 

the ideal universal internal cylindrical grinding machine in this segment. 

Its specialty is the complete machining of workpieces with a length of up 

to 550 mm (21.65 ") (including clamping devices) and a 0 of up to 420 mm 

(16.5 "). Thanks to the wheelhead with multiple grinding spindles and 

QuickSet for quick setup, it significantly reduces setup and resetting costs. 

The S100 is also easy and quick to control, with ergonomically arranged 

operating elements and StuderPictogramming. “Ease of use is also particularly 

important for entry-level machines”, says CSO Bottazzo. 

In numerous locations, shrinking and aging populations are making it 

increasingly difficult to replace retiring workforces who, through their years 

of experience, could achieve high quality with manual grinding machines. 

“Thanks to the innovative technology, intuitive software, and simple operation 

of our entry-level machines, our customers’ employees can grind workpieces 

of the highest quality after just a few days of training,” explains CTO 

Huber. 

Automation is also becoming increasingly important. It helps to save time 

and work for operators and makes overall production more efficient. For instance 

the favorit and the S100 can be equipped with a standardized loader 

interface, which can automatically open and close the operating door. “Customers 

can thus integrate the machine into their automated production 

processes, for example, with a robotic arm or a gantry loader,” says Huber. 

Wide range of applications 

As a globally established grinding machine manufacturer with over 111 years 

of tradition, STUDER is also well-acquainted with the varying regional 

requirements in the entry-level sector. “Besides high quality and precision, 

top reliability is particularly important. Our customers, particularly small 

and medium-sized enterprises, appreciate that they can grind highly economically 

with our machines, practically without any downtime”, says 

Bottazzo. Technical standardization not only ensures an economical price 

but also a low susceptibility to errors. Should a problem occur, STUDER’s 

customer-oriented and efficient Customer Care is quickly available to provide 

expert assistance. 

But what is the typical clientele for an entry-level machine? There isn’t one, 

thanks to the wide range of applications these machines cover. Whether it’s 

an automotive supplier at the highest international level like Celikis in Turkey 

or manufacturers of woodworking tools, hydraulic parts for the aviation industry, 

shafts for tractors, or tungsten carbide components for drawing dies: 

all this and much more can be achieved with STUDER’s entry-level machines 

– economically, efficiently and without compromising on quality. 

advantages of STUDER’s 

entry-level machines: 

➤ products with the highest STUDER quality 

and precision 

➤ attractive value for money with 

short delivery times 

➤ standardized grinding machines with 

various configurations 

➤ easier operation and simple maintenance 

for operators 

➤ machining of workpieces in 

different sections 

➤ grinding of threads or non-round shapes 

possible 

➤ optional integration of a loader interface 

and an automatic operator door, 

depending on the model 

favorit 

➤ CNC universal cylindrical grinding 

machine for the individual and 

batch production of short to 

long-sized workpieces 

➤ distances between centers of 

400/650/1000/1600 mm 

(15.7’’/25.6’’/39.4’’/63’’) and a 

center height of 175 mm (6.9”) 

➤ workpieces with a maximum weight of 

150 kg (330 lbs) 

➤ external and internal grinding possible 

in one setup 

favoritCNC 

➤ the CNC universal cylindrical grinding 

machine is a leader in value for money 

and suitable for universal use 

➤ distances between centers of 650 mm 

(25.6”) or 1000 mm (39.4“) and a 

center height of 175 mm (6.9”) 

➤ workpieces with a maximum weight of 

80 or 120 kg (176 or 264 lbs) 

➤ external and internal grinding possible in 

one setup 

S100 

➤ the ideal CNC universal internal cylindrical 

grinding machine for the entry-level 

segment covers a wide range of internal, 

face and external grinding applications 

➤ workpiece length (incl. clamping device) of 

550 mm (21.65”) and maximum workpiece 

0 of 420 mm (16.5”) 

➤ grinding 0 external: 

max. 420 mm (16.5”) / 

internal: max. 300 mm (11.8”) / 

grinding length internal: 

max. 200 mm (7.87”) 

further information: www.studer.com 


39


Designed for production 

A benchmark in cutting performance and precision 

With the presentation of the F 6000 5-axis machining 

center, HELLER has launched a new generation 

of the F series. The benefits: increased cutting performance 

and higher precision, maximum reliability for 

24/7 production, optimum ease of operation and a 

compact machine footprint. 

Dr. Eng. Manuel Gerst, head of development of the HELLER 

Group, adds: “With the F 6000 we have succeeded in raising 

the already high standard to a new level, also due to newly 

developed key components ‘Made by HELLER’ such as spindles, 

heads and tables whilst consistent standardization also 

helps us to ensure full compatibility with previous models.” 

Following intensive development work, HELLER’s new 

F 6000 5-axis machining center is available for order since 

September 2023. It can be used for all areas of 5-axis machining, 

including optional combined mill/turn operations, 

from heavy-duty cutting through to machining of 

light metals. The machine is just as efficient for the manufacture 

of single parts as it is for series production. As a 

result the F 6000 offers a compelling solution for companies 

in a wide range of industries – from general mechanical 

engineering, power train and power engineering through to 

aerospace. 

Dr. eng. Manuel Gerst, 

head of development 

of the HELLER Group: 

“With our new, powerful 

and compact F 6000 

5-axis machining center, 

we offer users even 

greater productivity 

and flexibility” 

With its modular design the F 6000 combines and extends 

the capabilities of the previous F series and the mill/turn machining 

centers from the C series. Topology-optimized structural 

components and the improved machine design guarantee 

high basic stability. With a wide range of options available, 

the machine can be optimally tailored to the needs of 

each individual customer, ensuring maximum productivity 

in practical use. 

Spindle units with in-house 

developed motor spindles 

The HELLER team, led by head of development Manuel Gerst, 

has made numerous improvements. Highlights of the new 

generation include the completely redesigned swivel heads 

with 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, the company offers the Dynamic 

User-friendliness is paramount with the new F 6000; 

the standard SINUMERIK ONE control contributes to this, 

as does the significantly wider door to the work area 

The completely redesigned swivel heads with integrated 

motor spindles, specially developed by HELLER, contribute 

significantly to the high accuracy and dynamics of the F 6000 



HELLER’s new F 6000 was unveiled at EMO 2023 

and is available for order since then 

The optional DDT (Direct Drive Turning) 

rotary table can reach speeds of up to 700 rpm; 

this allows simultaneous 5-axis machining 

and turning operations to be performed 

in a single set-up 

Cutting Unit (DCU) designed for universal 

use with 380 Nm and 12,000 rpm. For heavyduty 

machining, the Power Cutting Unit 

(PCU) with a gear spindle and 1,150 Nm is 

still available. 

Equally elementary is the revised drive concept 

of the linear axes, with two ball screws 

in the Z-axis and the significantly reinforced 

X-axis. “The machine offers much higher 

dynamics in the linear axes. At the same 

time the positioning tolerances have been 

greatly reduced for the PRO package. The 

new standard is 5 µm, with 4 µm available as 

an option. Tolerances on the rotary B- and 

C-axes have also been reduced and are now 

7 arc seconds as standard. Overall, this is 

reflected in the workpiece, reaching new top 

marks for accuracy and machining time”, 

explains Gerst. 

High-speed rotary table 

for complete machining 

The F 6000’s Mill-Turn option ensures greater 

precision and shorter production times for 

workpieces that also require turning in addition 

to complex milling operations. This is ensured 

by the high-speed DDT (Direct Drive 

Turning) rotary table available for the new 

machining center. It offers high torque and 

can reach speeds of up to 700 rpm. This means 

that, in addition to conventional milling 

and drilling operations, external and internal 

contours can be machined in a single setup 

using the turning functionality. The wide 

range of machining cycles covers virtually 

all the capabilities of a conventional turning 

machine. 

New hardware and software ensure 

greatest possible ease of operation 

Another major strength of the F 6000, according to Manuel Gerst, is the ease 

of use it offers in every respect. The comfortable main operating unit in console 

design with 24-inch touch screen and other features ensures that the 

operator quickly gets to grips with the machine. In addition, the signifi - 

cantly wider door to the work area provides easier access to the workpiece. 

Bright work area lighting, an additional LED light in the swivel head and an 

optional work area camera ensure good visibility when setting up new workpieces. 

The optional SETUP Assist allows new processes to be set up quickly 

and safely on the machine. 

The new Siemens SINUMERIK ONE control is available as standard. 

Existing NC programs from F- and C-series machines equipped with 

SINUMERIK 840D sl can be transferred directly and easily by the user. 

Manual Gerst: “Compatibility with our previous machines is very important 

to us. This means that tools, machine pallets and fixtures from our 4-axis 

and 5-axis series are compatible and can continue to be used on the F 6000.” 

Automation for every requirement – even as a retrofit solution 

The pallet changer, as the first level of automation, provides a reliable basis 

for automated series production of small, medium or large batches. The 

F 6000 is equipped with a pallet changer as standard and can easily be extended 

with a standardized linear or rotary storage. The new ‘Automationready’ 

option allows the HELLER rotary pallet storage (RSP) and HELLER’s 

standardized linear storage solutions to be retrofitted easily, cost-effectively 

and quickly – without having to modify the machine. 

Free chip fall below the spindle increases process reliability. To this end, 

the designers have incorporated a wide chip conveyor, steep covers in the 

work area and stainless steel cladding of the chip chutes to ensure effective 

chip evacuation. The new machine design, and in particular the direct chip 

disposal to the rear of the machine, has resulted in a significantly smaller 

footprint of the F 6000. The machine’s narrow width of 3.70 m is an advantage, 

especially when automating multiple machining centers and allows for 

a much better use of the available space. 

further information: www.heller.biz 


41


Nothing is impossible 

Optimized chamfering of internal gears 

during the machining process 

On the new LK 280 DC gear skiving machine from 

Liebherr-Verzahntechnik GmbH, internal gears can not 

only be produced efficiently, but also chamfered during 

the machining process thanks to an integrated 

ChamferCut device. This opens new opportunities for 

manufacturing gearboxes with higher power density, 

giving them a competitive edge in the market for modernized 

or alternative drive technologies. 

New drive designs require gearboxes with greater power 

densities, and not just for the electromobility sector. Planetary 

gears are therefore being used more and more frequently, 

which deliver a higher transmission ratio at a smaller volume. 

However, the possibilities for chamfering the internal 

gears required for this have been limited up to now. “There 

was a desire in the industry for economical and high-quality 

chamfering solutions for internal gears. But up to now these 

seemed almost impossible to put into practical use,” says 

Dr. Oliver Winkel, head of application technology at Liebherr- 

Verzahntechnik GmbH, describing the situation at the get-go. 

Now the company is first in presenting a machine which 

does exactly that: by making use of an exciting new cutting 

method to make a defined, exact chamfer on an internal 

gear – and to do just that during the machining process and 

with high precision to boot. In this way previously formed 

burrs are removed and, at the same time, the leading edges 

are broken, which creates the best conditions for assembly, 

application behavior or any subsequent hard gear finishing. 

Modular machine design with pick-up spindle 

This is made possible by Liebherr’s modular machine design, 

which allows the ChamferCut device to be integrated into 

the machine. The chamfering device is at a right angle to the 

main machining and is fed by a ringloader. For the particular 

requirements of chamfering internal gears, Liebherr has 

developed a new type of pick-up spindle that lifts the workpiece 

and thus makes the burred underside of the internal 

gears accessible for the ChamferCut tool. “That’s where our 

strength lies; in developing innovative solutions and new machine 

designs for new component requirements. The knowhow 

was there, and the first customer inquiry got the ball 

rolling. We were offered the opportunity to make a machine 

just for this purpose,” explains Winkel. The gear skiving 

machine with integrated chamfering device is already in use 

at a well-known gear manufacturer. 

Tried and true ChamferCut tools from LMT FETTE 

“The tool manufacturer LMT FETTE, which exclusively supplies 

us with ChamferCut tools, had the tools for chamfering 

internal gears (ChamferCut IG: Internal Gear) in its product 

range. We then developed and built the machine for this, 

so to speak,” Winkel continues. “The customer approached 

us because they had good experience with our gear skiving 

tools in the past and trusted us to provide the solution for the 

new requirements.” Another new feature of the machine was 

that it also allows clean and environmentally friendly dry 

machining during gear skiving and chamfering. With this, 

Liebherr offers a machine for economical and series production 

of internal gears with a defined chamfer. 

Versatile: one machine, two technologies 

But the machine is also suitable for changing between large 

and small batch sizes with a higher part variance. The 

changeover to the FlexChamfer process, in which the chamfer 

is generated by CNC-control with standard shank cutters, 

is easily realized with a simple switchover of the control 

system and opens up the greatest possible versatility in the 

application. “You only have to retool the machining head and 

switch between software programs. So you practically get one 

machine with two technologies and can produce large series, 

but also prototypes and small series economically and efficiently,” 

states Martin Schwarzmann, product manager for 

gear technology. 

ChamferCut IG as a stand-alone solution 

ChamferCut technology for chamfering internal gears can 

also be integrated into existing production processes as a 

stand-alone solution. The chamfer machines in the LD series 

are designed for either dry or wet machining and can be 

combined with various automation options. Winkel sums up, 

“With our machine design, we have succeeded in developing 

an innovative solution for the component requirements of 

current and future planetary gears.” 

further information: www.liebherr.com 



New peripheral and double T-land grinding machine 

for the European market 

After taking over the RETROFIT responsibility 

for top and bottom, grooving 

insert/plunge-cut and profile grinding 

machines of WENDT GmbH (3M 

Group) in 2017, HDC Huttelmaier GmbH 

is adding a new machine to its machine 

portfolio for this year’s GrindingHub. 

This is the CPG400 peripheral and double 

T-land grinding machine for the 

European market, and it completes 

HDC’s program for the main grinding 

applications on inserts from the blank to 

the finished product. 

Grinding machine 

CPG400 

HDC thus offers an alternative with an excellent 

price-performance ratio in this previously 

one-sidedly dominated market. The European 

market launch will take place with the presentation 

at GrindingHub (May 14.-17., 2024) in 

Stuttgart, on the HDC-booth in hall 9. 

The facts 

The automated, 4-axes peripheral and doublesided 

T-land grinding machine CPG400 is 

perfect especially for ultra-hard materials 

such as PCD, PCBN, ceramics, cermets, etc. 

The basic machine which has been in use in 

Asia x-100 times for years and is constantly 

being developed further, is built by LMT in 

China. The high reliability and repeat accur- 

Robot load 

acy of the CPG400 is largely the result of established German and Japanese 

brand components. The latest updated version of the CPG400 is now also 

available from HDC Huttelmaier for the domestic market. 

In addition to implementing European standards, HDC, as an experienced 

specialist for grinding machines, is responsible for CE certification and technical 

implementation. HDC also offers the adaptation of the machine to 

individual demands and acts as contract and service partner. After the 

GrindingHub, the CPG400 will also be available for grinding tests in the 

HDC showroom in Schorndorf (near Stuttgart). 

Workroom dressing wheels 

further information: www.huttelmaier.de 


43

components 

Innovative cutting oils for 

non-ferrous metal processing 

Lubricant manufacturer Zeller+Gmelin is launching 

four new high-performance cutting oils for nonferrous 

metal processing: Multicut Grind HP 15 NF for 

cylindrical or profile grinding, Multicut FSE 

HSC 15 NF for demanding high-speed machining, Multicut 

Basic HP 15 Extra NF as a universal product for steel and 

non-ferrous metals, as well as Multicut Plus 10 NF as an allround 

cutting oil for conventional, medium-duty machining 

tasks. Thanks to their special formulation they easily cope 

with the special requirements when machining non-ferrous 

metals and at the same time deliver first-class results in terms 

of tool life and performance. 

Sulphur additives are actually known to increase the performance 

of non water-miscible cooling lubricants. However 

the resulting metal sulfide layer, which normally reduces wear 

during machining and improves lubrication, proves to be extremely 

counterproductive when it comes to non-ferrous 

metals. Copper and copper-containing compounds such as 

bronze or brass in particular react sensitively to sulphur compounds. 

The consequences are increased corrosion, black 

spots, discolored components and inferior part quality. And 

this in turn leads to disruptions in the production process, 

longer downtimes and waste of raw materials. 

Sustainable and resource-saving cutting oils 

With the special NF products from the Multicut portfolio, 

Zeller+Gmelin has specialized in lubricants that meet 

the technical challenges in non-ferrous metal processing. 

According to the manufacturer they are ideal for metal processing 

from turning, milling and drilling to thread processing 

and deep hole drilling. At the same time the experts are 

constantly working to increase the efficiency, quality and sustainability 

of their cutting oils. And they are also looking for 

new, sustainable formulations – relying increasingly on contemporary 

base oils such as hydrocracking oils and resourcesaving 

esters. 

Machining economically 

“With Multicut we fully meet the increased requirements of 

a modern industry, because our cutting oils deliver excellent 

results even with demanding materials and in delicate machining 

processes,” emphasizes Dr. Irene Kreitmeir, product 

manager for lubricants at Zeller+Gmelin. Many of the extended 

formulations of the Multicut NF products are not only 

suitable for the most demanding machining tasks and difficult-to-machine 

materials, but also specifically for the 

machining of sensitive non-ferrous metal alloys, such as 

beryllium copper, which is so often used in the watch industry. 

“A decisive factor of our Multicut NF cutting oils is the 

reduced consumption,” explains Dr. Irene Kreitmeir. “Due to 

Used in particular by watch manufacturers: 

the new high-performance cutting oil 

Multicut FSE HSC 15 NF from Zeller+Gmelin 

is compatible with non-ferrous metals and 

is suitable, for example, for beryllium copper 

(source Pixabay) 

the low oil mist formation and the low evaporation loss, oil 

consumption is reduced immensely, which means that companies 

can save costs in the long term.” Additionally there is 

the low foam formation and the good air separation capacity, 

which ensures uniform lubricating properties and thus 

leads to improved machining qualities and longer tool life. 

The high flash points of the Multicut NF cutting oils also 

ensure increased safety during handling and reduce the risk 

of fires or injuries. 

A range for all requirements 

The Multicut NF cutting oils are particularly suitable for sensitive 

non-ferrous metal alloys, but also for soft free-cutting 

steels, case-hardened and tempered steels and sometimes 

even for high-strength, acid- and rust-resistant steels. 

The high-performance grinding oil, Multicut Grind HP 15 

NF is ideal for various machining processes such as cylindrical 

or profile grinding. It offers a high pressure absorption capacity, 

good wear protection and guarantees excellent surface 

quality. It is not only suitable for grinding non-ferrous 

metals, but can also be used in machines that process nonferrous 

metals. In addition an approval from the grinding 

machine manufacturer Junker in Nordrach is available. 

further information: www.zeller-gmelin.de 


Support-free 3D printing opens up new 

applications and reduces waste 

components 

High-tech company TRUMPF recently 

made improvements to its 3D printing 

software TruTops Print. Users can now 

print parts with extreme overhang angles 

as low as 15 ° without requiring support 

structures. TRUMPF showcased its 

new technology at EMO. 

“The latest version of TRUMPF’s TruTops 

Print software eliminates the need for virtually 

all support materials, which ultimately 

means quicker builds and lower material 

consumption,” says Lukas Gebhard, process 

development engineer for additive manufacturing 

at toolcraft. “Support-free printing 

gets parts close to their final shape. It opens 

the door to parts and projects that were previously 

impossible, such as the near-netshape 

manufacturing of large-diameter internal 

cooling channels.” In the past users had 

to print support structures together with the 

part in order to anchor the part to the build 

platform. These structures also serve to dissipate 

heat from the printed part and prevent 

internal tensions and deformations during 

printing. But this innovative new technology 

means that many 3D printing applications 

can now be carried out without supports, 

even when tackling hard-to-process materials 

such as stainless steel. 

Software opens up new 3D 

printing strategies 

“When we 3D print a part, we want as much 

control as possible over when and where the 

material melts and re-solidifies. The skill lies 

in choosing the right exposure strategies to 

prevent internal tensions and overheating in 

the overhang region,” says Timo Degen, product 

manager for additive manufacturing. 

TruTops Print enables the 3D printer to use 

the optimum printing strategy for every different 

area of the part, thus eliminating the 

need for support structures. At the same time 

the improved gas flow of the new 3D printers 

caters to uniform processing conditions and 

support-free printing. 

Support-free 3D printing 

opens up new applications 

“Users from any industry can benefit from 

the ability to 3D print parts without supports. 

TruTops print allows users to print parts with extreme overhangs 

as low as 15 ° without requiring support structures 

The advantages of support-free printing are particularly appealing 

for parts that feature large cavities or challenging overhangs 

The advantages of support-free printing are particularly appealing for parts 

that feature large cavities or challenging overhangs,” says Degen. Examples 

include tanks, heat exchangers, hydraulic blocks and tool molds. 

The new technology also opens up new applications that couldn’t be properly 

exploited when support structures were still necessary, including areas 

such as additively manufactured radial compressors and shrouded impellers. 

Previously manufacturers were unable to print support-free impellers due to 

their overhang angles. “The need for supports meant that 3D printing wasn’t 

an economically viable alternative to conventional manufacturing. But now 

things are different,” says Degen. 

further information: www.trumpf.com 


45

components 

New precision clamping fixture simplifies 

turning and milling processes 

More flexibility in machining production 

and significantly reduced setup 

times – these are the premises under 

which RINGSPANN presents the new 

HSFS 110 clamping sleeve chuck. This innovative 

precision clamping system offers 

numerous advantages, especially for 

users of turning/milling machines with 

main and counter spindles and machine 

tools with bar loaders. 

Since it does not require pull-back action, it is 

equally suitable for machining bar stock and 

material sections in the first or workpieces 

from the second clamping step. 

“The aspects of increasing flexibility and reducing 

setup times were the focus of our considerations 

for a new clamping system for use 

in machining production”, says Christoph 

Schulz, product manager clamping fixtures 

at RINGSPANN. As a concrete result of 

the development work the company is now 

presenting the HSFS 110 clamping sleeve 

chuck, which is of interests both machine 

builders and users. The new precision clamping 

system from the company offers considerable 

efficiency advantages, especially when 

using machine tools with fully automatic 

barfeeders and turning-milling machines 

with two spindles. Including is the fact that it 

works without pull-back action – a technical 

prerequisite for use with bar loaders – and that 

its design allows for a very simple and quick 

replacement of the clamping sleeves. 

With clamping diameter range from 22 mm 

to 80 mm, the new HSFS 110 from the company 

is an extremely versatile clamping fixture 

for many different tasks. It also provides 

the user with additional flexibility, not least 

because it allows the clamping diameter to 

be changed by up to 1.5 mm. “Our HSFS 110 

allows for large workpiece tolerances and insertion 

clearances. It is therefore also suitable 

for automated loading”, explains Christoph 

Schulz. 

Christoph Schulz, product manager Clamping 

Fixtures at RINGSPANN: “Since our new 

HSFS 110 clamping sleeve chuck allows 

for large workpiece tolerances and 

insertion clearances, it is also 

suitable for automated 

loading.” 

draw tube 

adapter 

adapter flange for 

spindle heads 

basis chuck 

backstop plat 

(optional) 

clamping 

sleeve 

The new HSFS 110 clamping sleeve chuck from RINGSPANN is a 

purely mechanical clamping system and consists of a base chuck, a 

clamping sleeve as well as a draw tube adapter and an adapter flange 

Clamping principle of the new HSFS 110: preloaded clamping discs 

are located in an axially movable holder; during clamping, the holder 

is shifted axially, the clamping discs straighten up and the clamping sleeve 

rests against the workpiece; in this process, the workpiece is centred, 

and the axial actuating force is translated into a radial clamping force 

that is up to ten times greater 


components 

The new HSFS 110 clamping sleeve chuck offers 

more flexibility in machining production and 

enables significantly reduced setup times 

The new HSFS 110 offers efficiency advantages, 

especially in tool making with fully automatic bar loaders 

and turning-milling machines with two spindles; it works 

without pull-back action and allows for easy, 

quick replacement of the clamping sleeves 

Clamping sleeve as an interchangeable part 

The new HSFS 110 clamping sleeve chuck is a purely mechanical 

clamping system and consists of a base chuck, a clamping 

sleeve as well as a draw tube adapter and an adapter 

flange. While the adapter flange connects the machine spindle 

to the base chuck, the draw tube adapter transfers the actuating 

force from the clamping force device of the machine 

spindle into the base chuck. The clamping sleeve is an interchangeable 

part that can be replaced easily, quickly and as required 

without special tools. "In addition, the use of individually 

designed stop plates makes it possible to load and process 

workpieces axially positioned from the front. That is why 

the HSFS 110 is also usable for material sections in the first 

clamping step without any problems,” says Christoph Schulz. 

The clamping principle of the new HSFS 110 can be described 

in a few words: clamping discs with preload are 

located in an axially movable mount. If the holder is then 

shifted axially during clamping, the clamping discs straighten 

up and the clamping sleeve firmly clamps the workpiece. In 

this process the workpiece is centered, and the axial actuating 

force is translated into a radial clamping force up to ten 

times greater. The maximum torque achievable depends on 

the diameter of the bar material to be machined. Two limits 

provide orientation: rods with 0 of 80 mm are clamped at 

up to 470 Nm, while the maximum torque for rods with 0 of 

22 mm is 85 Nm. “At the same time the chuck of the HSFS 110 

ensures uniform, safe and precise 360 ° clamping around the 

workpiece at all times,” emphasizes Christoph Schulz. In 

numerous tests the HSFS was able to attest to an extremely 

smooth running. 

Sleeves, flanges and plates for all occasions 

The specific size of the HSFS 110 clamping sleeve is defined 

by the rod’s diameters or the sections and workpieces that 

are to be machined. As standard the company offers a selection 

of 28 different clamping sleeves for as many diameters of 

rods (according to EN 10278) or cylindrical workpieces. The 

clamping sleeve can be changed in just a few simple steps, no 

special tools are required – an Allen key is sufficient! 

The adapter flanges for connection to the spindle heads of 

various machine tools are always designed by RINGSPANN 

according to customer requirements. According to Christoph 

Schulz, “short flanges for short-cone connections are also 

part of the range”. 

The draw tube adapters are also adapted to the specific case – 

here the spindle geometry and the design of the draw tube of 

the power clamping device serve as decisive specifications. As 

indicated before, the stop plates can be individually designed 

for front loading with material sections or workpieces. 

With the new HSFS 110 clamping sleeve chuck manufacturers 

and users of machine tools are being offered a modern 

precision clamping system, on which many turning and 

milling processes of the first and second clamping step can 

be carried out extremely flexibly and efficiently. Thanks to 

its high adaptability and easy handling it is also one of those 

clamping systems that can give the machining of workpieces 

a noticeable economic efficiency impulse. 

further information: www.ringspann.de 


47

components 

High-performance coolant filtration for 

consistent quality in the production of mini tools 

In order to precisely grind microtools with extremely 

small diameters, an optimally coordinated 

overall cutting system is required. One quality-determining 

piece in the mosaic is micro-filtration of the 

coolant. 

This is because the smallest impurities in the grinding oil 

or temperature fluctuations in the medium have a negative 

effect on the quality of the grinding result. The filter manufacturer 

Vomat from Treuen offers the necessary filter technology 

to meet the specific performance requirements in 

micro tool production: Vomat filters deliver highly filtered 

grinding oil in purity class NAS-7 (3-5 µm) over a long application 

period. In addition, they ensure precise control of the 

coolant temperature. 

The continuing trend towards miniaturization of devices 

and components in various industries requires the use of 

extremely small and high-precision tools in production. For 

example, in order to grind reliably drills, milling cutters and 

gauges etc. with their wafer-thin shanks and filigree geometries 

in large-scale production, the production conditions 

and technologies in conjunction with comprehensive quality 

assurance play a decisive role. State-of-the-art grinding, 

measuring and edge preparation technologies, ideally in temperature-constant 

production halls, complement each other 

perfectly and result in mini tools that meet the extreme 

requirements of the industry in terms of surface quality and 

concentricity. 

The filter 

manufacturer Vomat 

offers ultra-fine 

filtration technology 

that provides clean 

coolant media in 

NAS-7 quality with 

high control accuracy 

and is therefore 

particularly suitable 

for the production 

of miniature tools. 

“An important factor in this sensitive production environment 

is ultra-fine filtration of the cooling lubricants”, as 

Steffen Strobel, sales manager at Vomat, points out. “When 

grinding microtools, contaminated or insufficiently filtered 

cooling lubricants can have a sensitive effect on the grinding 

result. Even minimal temperature fluctuations in the cooling 

lubricant pose a major threat to the final quality as they can 

have a negative effect on the expansion behavior of machine 

components and tool substrates. Vomat’s filter technology is 

designed to eliminate precisely such disturbing factors and 

ensure optimum filtration. 

Trend-setting filter technology 

Vomat filters separate 100 % dirty and clean oil in full flow. 

This means that the tool manufacturer can always work with 

clean cooling lubricants. In addition Vomat systems carry 

out backflushing as required. The degree of contamination of 

each individual filter element is monitored, and if a defined 

value is exceeded the backflushing process is automatically 

initiated. 

Meanwhile the other filter elements ensure a continuous 

supply of clean oil in cleanliness class NAS-7 (3-5 µm). This 

advanced capacity control of the filter system helps to optimize 

energy consumption and thus lower operating costs for 

the grinding process. Precise temperature monitoring of the 

grinding oil with a control accuracy of +/- 0.2 K ensures constant 

optimum temperatures of the coolant media. 

The design advantages of the Vomat filters used play an important 

role in process-reliable production with reproducible results, 

especially the high control accuracy and precise temperature 

monitoring of the grinding oil when grinding microtools 

Steffen Strobel: “If the tool manufacturer relies on the 

latest grinding technology for grinding microtools, he cannot 

do without forward-looking fine filtration. Only in this 

way he can produce the high qualities that the industry 

requires.” 

further information: www.oelheld.com 


components 

Motorview process visualization system proves its 

worth in the semiconductor industry 

A core topic of Industry 4.0 is and remains the 

monitoring and control of manufacturing and 

machining processes. MotorView, developed by 

BMR elektrischer und elektronischer Gerätebau GmbH 

(BMR for short) in 2020, offers a powerful solution for 

integrating a process monitoring system for converters 

and motors and is suitable for all applications in 

which a spindle converter system is used. 

These include milling machines, for example where several 

operations are often carried out with different milling cutters 

and it is particularly important to track each individual 

processing step directly. MotorView has already proven itself 

successfully in various applications and has been in use at 

Schaeffler Aerospace for many years. 

First application in wafer production 

The BMR process visualization system, which is worldwide 

unique in terms of its efficiency, flexibility and compactness, 

is now being used for the first time in the semiconductor industry, 

specifically at Genauigkeits-Maschinenbau Nürnberg 

GmbH (G&N for short). The company develops and produces 

precision surface grinding machines for the machining of 

metals, ceramics, silicon and other materials where machining 

is particularly demanding. Since fall last year, almost all 

automatic machines and new developments have been offered 

together with MotorView. The detailed test phase directly on 

MotorView 

Grinding at G&N 

site in production has already shown that the BMR system 

continuously achieves repeat accuracies of 5 μm on average 

when grinding wafers. A further advantage became apparent 

when retrofitting existing machines on site, as the motor 

phases only had to be looped through the device once, eliminating 

the need for time-consuming and space-consuming 

retrofitting. 

“With this BMR system we offer our customers added safety 

and saved time”, says G&N managing director Hermann 

Moos. “This new application shows that it is worth to use in 

a wide range of high-tech applications”, explains Stephan 

Brittling, managing director of BMR, responsible for coordinating 

the test phase and customer support on site. “Also 

here our product will soon be amortized”, continues Stephan 

Brittling. 

MotorView consists of two components and is therefore 

easy to install: the sensor part is clamped or looped into 

the motor cables between converter and driven motor. As a 

result the motor phases run via the device, which records and 

stores all information about voltages and currents without 

affecting the process. The display part is connected via 

cable and graphically displays the recorded load status of the 

spindle. Digital and serial interfaces are available for communication 

and integration with the machine control system. 

In the long run the system contributes to cost reduction in 

production in the sense of “predictive maintenance”. For 

example it enables the user to change tools in good time by 

detecting reductions in cutting performance due to blunt 

tools at an early stage. Furthermore it immediately detects 

bearing fade of the spindles, the failure of a motor cable, the 

detection of control oscillations or parameterization errors in 

the drive system. 

further information: www.bmr.gmbh 


49

components 

Multisensor technology 

perfectly integrated 

The VideoCheck® S from Werth Messtechnik now offers even 

greater flexibility. The multisensor coordinate measuring machine 

can additionally be equipped with up to three independent sensor 

axes and a stepless, multisensor-capable rotary/tilt head. 

With the high-precision machines of the Werth VideoCheck® series the 

potential of even the most accurate sensors can be fully exploited. Werth offers 

unique high-precision sensors, as the patented Werth Fiber Probe® 3D 

or the Werth Interferometer Probe. The proven multi-ram concept for maximum 

flexibility when using multisensor technology is now also available 

for the smallest machine in the series, the VideoCheck® S. The new machine 

concept makes it also easy to retrofit suitably prepared purely optical or 

purely tactile machines with multisensor technology. 

This means that the accessibility of workpiece geometries is no longer restricted 

by other sensors or accessories. The independent sensor axes enable 

fast measurements without sensor changes. Since the axes with the nonactive 

sensors are outside the measuring range, the risk of collision is minimal. 

Sensor changing stations are no longer necessary, so that the measuring 

range can be used without restriction. It is possible to remove the changing 

stations from the measuring volume after the sensor change using the machine 

axes, but that time is also eliminated. 

Werth coordinate measuring machines offer high flexibility with various 

options. With the Werth Multisensor System different sensors can be 

swapped in at the same position in front of the image processing beam 

path. This means that the combined multisensor measuring range can 

be used without restriction, even with additional sensors, and the risk of 

Fast multisensor 

measurements 

without restrictions 

with the multi-ram 

concept on the 

VideoCheck® S 

collision is minimal. The new, multisensorcapable 

Werth Rotary Tilt head enables fast, 

stepless positioning of sensors. For example, 

very steep flanks can now be measured with 

optical sensors as well. The eccentric probe 

mounting also allows the use of rotary/tilt 

heads on smaller machines. Workpiece rotary 

or workpiece rotary/tilt axes can be mounted 

in any direction. The multi-ram concept optimizes 

accessibility and minimizes the risk 

of collision. 

The new machine is suitable for mediumsized 

workpieces with tight tolerances and 

different geometric properties that require 

the use of multisensor technology. Examples 

include large plastic housings of automotive 

electronics, cutting inserts, micro hobs, shaft 

tools, optical lenses or dental implants. 

further information: www.werth.de 

Ultra black laser marking for medical technology 

US-product premiere at the trade show: FOBA Laser Marking 

+ Engraving Solutions presented its ultrashort pulse laser for ultrablack 

laser marking for the first time in the United States at MD&M 

West (Anaheim, CA, February 6-8, 2024). 

“After the successful premiere in Europe we are proud to present our new 

product to our customers in the USA. The FOBA ultrashort pulse laser produces 

deep black markings that are particularly gentle on materials, making 

it a real asset for the medical technology market in particular,” reports 

Philipp Febel, head of product management at FOBA. 

The ultrashort pulse laser F.0100-ir marks in a deep, matt and non-reflective 

black without generating significant heat on the workpiece. Through 

further processing steps, such as passivation, the marking remains reliably 

legible and corrosion resistant. Due to the very short pulses down to the 

femtosecond range, together with high pulse energies, the system marks 

stainless steels, titanium and a variety of plastics. The compact laser can be 

integrated into FOBA’s M-series; it was shown at the trade fair in an M2000 

workstation. 

“We want to 

actively support our customers 

with the current and upcoming 

UDI labeling standards,” says Jeffrey A Kniptash, 

sales manager Americas at FOBA. According 

to FDA regulations all reusable and reprocessed 

medical devices must bear a directly 

marked UDI (unique device identification), 

meaning a unique numeric or alphanumeric 

code. “We offer expert advice on this topic, 

and thus facilitate the implementation and 

validation of a secure laser marking process,” 

continues Jeffrey A Kniptash. 

further information: www.fobalaser.com 


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Maschinenfabrik GmbH ........ 19, 40 

Global Industrie 2024. ...............22 

Hartmetall-Werkzeugfabrik 

Paul Horn GmbH ..................10 

Huttelmaier GmbH . . . . . . . . . . . . . . . . . .43 

Hyperion Materials & Technologies, 

Inc. ...............................11 

KAPP GmbH & Co. KG. . .............32 

Lach Diamant Jakob Lach 

GmbH & Co. KG ...................26 

Liebherr Verzahntechnik GmbH . .... 42 

company finder 

MAPAL Fabrik für Präzisionswerkzeuge 

Dr. Kress KG .................. 12, 25 

Mikron AG, Division Tool .............6 

oelheld U.S., Inc. ................... 48 

Okuma Europe GmbH ...............21 

OTEC Präzisionsfinish GmbH ........37 

Platinum Tooling Technologies, Inc ....19 

RINGSPANN GmbH ................ 46 

SPR Abrasives GmbH ................16 

TRUMPF SE + Co. KG ...............45 

UCIMU-SISTEMI PER PRODURRE ..21 

UNITED GRINDING Group ........ 24 

VDW Verein Deutscher 

Werkzeugmaschinenfabriken e.V.. ..17, 22 

VOLLMER WERKE Maschinenfabrik 

GmbH . ........................ 23, 36 

WEILER Abrasives GmbH. .......... 24 

Werth Messtechnik GmbH. ...........50 

ZECHA Hartmetall-Werkzeugfabrikation 

GmbH. ...........................14 

Zeller+Gmelin GmbH & Co. KG. ..... 44 

The articles contained in this magazine, 

including the illustrations, are subject 

to copyright law. Any use without the 

consent of the publisher is not permitted 

and will be prosecuted. This applies to 

every conceivable form of reproduction. 

Copies and reprints can be ordered on 

request. Articles which are identified by 

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author by an abbreviation do not necessarily 

reflect the opinion of the editorial staff. 

Unsolicited manuscripts cannot be returned. 

If a manuscript is accepted by the editorial 

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as all rights for publication and distribution 

are transferred to the publisher. The 

publisher accepts no liability with regard 

to the facts set out in these articles. 

copyright © 2024 Dr. Harnisch Publications 

advertising index 

Boehlerit GmbH & Co. KG ...............................................page 13 

Kapp GmbH & Co. KG ..................................................page 11 

Lach Diamant Jakob Lach GmbH & Co. KG ....................... inside front cover 

Mikron AG, Division Tool ............................................front cover 

SPR ABRASIVES .................................................... back cover 


51

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hpt 2024 #1

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