ISSN 2628-5444

high precision tooling

Machine Tools, PCD, PVD, CVD, CBN, Hard Metal 2020 - 3

■ Diamonds show profile ■ Adhesive bonding as opportunities for cutting tool manufacturers ■
■ Robot cell increases productivity ■ Contactless processing ■ Resource-saving grinding oil filtration ■
 Four-edged
Titanbearbeitung
in Perfektion
Powerhouse
MonsterMill
The WTX HFDSTCR is
– damit
the Standzeit und
Prozesssicherheit
Number 1 in solid carbide
stimmendrilling

Find out more at:

cutting.tools/en/wtx-hfds

CERATIZIT is istaeine
high-tech
Hightech-Engineering-
engineering group
Gruppe, spezialisiert
specialising in cuttingauf
tools
Werkzeug-
and hard und
material
Hartstofftechnologien.
solutions.
TEAM CUTTING TOOLS
Tooling the Future
www.ceratizit.com
editorial

Say hello to
colleague robot
PROCESS TECHNOLOGY & COMPONENTS

Neither IMTS nor AMB could be carried

out this year. Not a reason to withhold
the novelties from our readers! After all,
the R&D departments of most companies
worked towards these fairs, where they
wanted to present their innovations to
Eric Schäfer the public and which you can now find
editor-in-chief in the hp tooling.

© SEEPEX
Innovations such as a 6-axis tool and cutter grinder, an all-round
talent for laser micro-machining, an advanced face milling system
for brilliant finishing or the humanoid industrial robot that smiles
at you from our cover, introduced by the grinding machine
manufacturer Rollomatic.

Such a robot is considered a real “partner” at work and can be

installed easily without redesigning a production line. Colleague
Robot is an example of the increasing automation of many machining
centers to increase their productivity. There is hardly a machine tool
manufacturer who does not offer automation for his machine tools.

In the end, it‘s all about saving time, reducing costs and producing
quality in an environmentally friendly way with the right tools,
machine tools and components. To achieve these goals, it does not
always have to be the latest technical development.

A CNC upgrade can also get a lot out of older machines. This is
shown by the experience of a US tool manufacturer through a suitable
software update on its 5-axis grinding machines.

How machine tool and tool manufacturers in particular can

benefit from each other can be read in our lead story, which deals
with a development partnership between machine manufacturer The cross-sectoral media platform
and tool manufacturer. for suppliers and users in two languages:
German and English
Remember to look at www.harnisch.com!
Exclusive information around the pump
and compressor industry as well as
systems and components

Developments and trends

First-hand future technology

Targeted at international trade shows

Eric Schäfer for 2020
editor-in-chief
Special issue for the Russian market
in October

Dr. Harnisch Verlags GmbH · Eschenstr. 25

90441 Nuremberg · Tel.: +49 (0) 911 - 2018 0
info@harnisch.com · www.harnisch.com
table of contents

lead story
Conceived from the process
A development partnership between a machine manufacturer
and a tool manufacturer 6

materials & tools

Fast process for Ni-based alloys 8
Getting chips under control 9
DTM milling system for brilliant-finish machining 10
Efficient machining of titanium 11
A fresh take on inside deburring 15
LACH DIAMANT looks back on 95 years - 5th part - Diamonds show profile 16

processes
Adhesive bonding: Opportunities for cutting tool manufacturers
Michael Stroka, Thomas Götz and Andreas Gebhardt 24
FT gearing count on Studer Grinders - the count is now 16! 28
Brilliant performance in countersinking in CFRP, GFRP and composites 30

machining center
Perfect manufacturing - robot cells increase productivity 32
Solid PCD Endmills, a new opportunity for increased productivity 35
Contactless processing 36
Next generation of 6-axis tool and cutter grinder 38

components
Reducing the ecological footprint in tool production 41
CNC upgrade program provides US cutting tool manufacturer with major productivity advantage 44
Ionized, cooled air to replace metalworking fluids 47
Increasing the efficiency and agility of machining companies 48

departments
fairs 5, 21
companies 20
impressum & company finder 50

4 no. 3, September 2020

fairs in alphabetical order with original date postponed to

AMB Stuttgart, Germany September 13-17,

(September 15-19, 2020) 2022

bauma CHINA Shanghai, China

not postponed
(November 24-27, 2020)

CCMT Shanghai, China completely

(April 7-11, 2020) cancelled

EPHJ Genf, Switzerland completely

(June 16-19, 2020) cancelled

FABTECH Toronto, Canada June 14-16,

(June 14-16, 2020) 2022

FEIMEC São Paulo, Brazil May 3-7,

(May 5-9, 2020) 2022

GrindTec Augsburg, Germany November 10-13,

(March 18-21, 2020) 2020

Hannover fair Hanover, Germany April 12-16,

(April 20-24, 2020) 2021

IMT Brno, Czech Republic September 13-17,

(October 5-9, 2020) 2021

IMTS Chicago, USA September 12-17,

(September 14-19, 2020) 2022

intertool Vienna, Austria May 10-13,

(May 12-15, 2020) 2022

JIMTOF Tokio, Japan

not postponed
(December 7-12, 2020)

METALEX Bangkok, Thailand

not postponed
(November 18-21, 2020)

Metalloobrabotka Moscow, Russia May 24-28,

(May 25-29, 2020) 2021

Metallurgy Russia + Moscow, Russia June 8-10,

Litmash Russia (June 9-11, 2020) 2021

METAV Düsseldorf, Germany March 23-26,

(March 10-13, 2020) 2021

SIMTOS Goyang, South Korea completely

(March 31-April 4, 2020) cancelled

Stone+tec Nuremberg, Germany May 12-15,

(June 17-20, 2020) 2021

Surface Stuttgart, Germany June 21-23,

Technology (June 16-18, 2020) 2022

TIMTOS Taipeh, Taiwan

not postponed
(March 15-20, 2021)

TMTS Taichung, Taiwan

not postponed
(November 10-14, 2020)
trade fair dates as by end of August, 2020;
we are not responsible for reliability of these dates

no. 3, September 2020 5

 lead story
Conceived from the process
A development partnership between a
machine manufacturer and a tool manufacturer
The larger the series of parts to be produced,
the more important are cycle times and tool costs.
With large quantities, as for the car industry, the
properties of both the machine tool and the tool
itself need to be optimally suited to each other -
and to the chosen manufacturing process.
“We have a unique approach when we receive customer
inquiries,” says Meinolf Wolke, Sales Team Leader at
ELHA-MASCHINENBAU Liemke KG (ELHA) in Hövelhof.
The medium-sized, owner-managed special machine con-
struction company places the workpiece and its machin-
ing at the centre of development and devises an optimal
solution perfectly designed for the process sequence. “In
doing so, we take all the technical and economic require-
ments into account,” clarifies Wolke further. Only then do
those responsible decide whether an existing machining
concept can be used for the process or whether an individ-
ual, application-specific construction is required. Meinolf
Wolke explains: “As well as providing the machine, we of-
fer services that stretch from process development and the
construction of fixtures all the way through to complete,
ready-to-operate solutions with automation and produc-
tion support.”
Special tools for low total costs
“The machining tasks are often as unique as the parts
themselves - including in terms of the workpiece materials,”
A peek inside the interior of Arrangement of four step drills
a production module reveals on the right-hand side of
that it features two spindle the working area of a
row revolvers (left) as well production module
as two quadruple spindle [photo provided by ELHA]
rows overhead
6 no. 3, September 2020
adds Alexander Wiesner,
Technical Advisor at
MAPAL. “Of course, a lot
of machining work on
com­ plex parts can be
achieved with standard
tools. But that often
comes with significant
draw­backs in terms of cy-
cle times, quality, and
cost-effectiveness, partic-
ularly when large quanti-
ties are being produced.”
In these cases, special Carina Becker (left) and
tools that are precisely Jörg Rodehutskors (centre)
calibrated by MAPAL for with Alexander Wiesner
the machining task in in front of an FM3+Xhd
question are preferred. production module
“During the tool design phase, it’s essential to determine
the necessary parameters for the machining process,” says
Wiesner, “particularly in the case of challenging geome-
tries.” In order to design the process in the best possible
way, MAPAL often makes prototype tools. These are then
used to carry out extensive tests with the part to be ma-
chined. “That, in turn, helps the equipment manufacturers
design the machine with the values identified during test-
ing,” continues Wiesner. He says that MAPAL has had a
long-standing partnership with ELHA in this area. The fol-
lowing three examples demonstrate the resulting benefits
to customers:
Solid drills for the machining
of suspension arms
“We were dissatisfied with the solution that we had been
using for drilling from solid in aluminium when machin-
ing a suspension arm, which included creating a fitting,”
remembers ELHA Project Leader Friedhelm Dresmann. The
company was then using tools with brazed PCD cutting
edges. In order to keep the machining time as low as possi-
ble, these drills were being used with very high feed rates.
The disadvantages of this solution were the high drive
power required and the insufficient durability of the PCD
cutting edges on the solid drill step. In search of a solution,
those responsible at ELHA turned to MAPAL. Together,
the employees of the machine manufacturer and the tool
manufacturer worked to find a solution. What they came
up with was a hybrid tool. The tip of the tool is equipped
with three-bladed, CVD-diamond coated, ISO-indexable
inserts for drilling from solid. The fitting is created using
brazed PCD cutting edges on the second step of the tool.
 lead story

Quadruple application
of disc milling cutters
on control arms
[photo provided Quadruple machining of
by ELHA] fuel-supply distributor
parts with deep hole drills
[photo provided
by ELHA]

MAPAL’s research engineers tested the new tool in their Deep hole drill for the machining of
own R&D centre. The results were impressive. In addition to stainless steel forged components
the lower costs of the indexable inserts overall, the posi­tive In order to optimise their processes, the customer asked
blade geometry meant that less drive power was required. ELHA to provide a solution in which the process described
The previous solution had often produced long metal chips - above, along with all other machining tasks, could be per-
with the new tool, this was no longer an issue. The index- formed on a single production module using multiple
able inserts at the tip of the drill, which are under signifi­ spindles. The parts should leave the production module in
cant stress, can be quickly and easily flipped or replaced. As ready-to-install condition.
a result, the maintenance costs were also noticeably reduced.
Altogether, the suspension arm manufacturers’ production ELHA enlisted MAPAL to assist with the bore process
costs for each drilled bore were reduced by over 50 %. previously discussed. The tool manufacturer was asked
to provide a drill that was able to carry out the machin-
Disc milling cutters for the machining ing more quickly, with less deviation and less wear and
of suspension arms tear. The MAPAL engineers developed a double-edged sol-
“We also worked with MAPAL to find an efficient solu- id carbide drill designed to meet the requirements per-
tion for machining forged suspension arms,” explains fectly. With application parameters of Vc = 90 m/min and
ELHA Project Leader Marcel Thieschneider. “Our goal was f = 0.5 mm, the new tool achieves a tool life of 80 meters
to develop process-reliable tools while maintaining the re- - almost three times as long as the solution previously
quired cycle times.” For the suspension arm, a yoke need- in use. Another special feature of the solution developed
ed to be created from the solid material at the end of the jointly by ELHA and MAPAL is that the workpieces in the
arm. During the required four-spindle machining process, clamping fixture rotate in the opposite direction to the
the long-chipping workpiece material demands very high drill during machining, which reduces the deviation of
drive power to the machine. In addition to this, the inter- the bore even further. This leads to significant cycle time
nal contour of the part features a number of angles and ra- bene­fits for the customer, who manufactures up to 5 mil-
dii, making the expulsion of chips during milling difficult. lion of these parts every year. And on top of that, they now
only need one machine to carry out all machining tasks.
“In order to ensure short process times, we developed
a disc milling cutter with ISO indexable inserts that en- Development partnership synergies
ables roughing and finishing with minimum quan- “These three examples demonstrate the benefits of our
tity lubrication in just one step,” recalls Alexander close collaboration with MAPAL,” concludes Carina Becker
Wiesner. The indexable from Technical Sales at ELHA. “And on top of that, the co-
inserts are coated with operation gives our design engineers additional freedom.”
CVD diamond. The pre- MAPAL’s specialists for the development of high-perfor-
cisely defined ar­ range­ mance tools, as well as their exceptionally well-equipped
ment of the indivi­ dual R&D department in Aalen, make it possible to develop and
inserts limits the drive intensively test new tool solutions even during the plan-
power required. After ning phase. That means ELHA is able to offer its customers
considering the compre­ even more well-engineered and economically advanta-
hen­sive tests at MAPAL geous solutions.
and the data that result-
ed from them, ELHA set
its machine to operate at ELHA-MASCHINENBAU Liemke KG
this drive power. A posi- is a family-run business that manufactures
tive side effect of using machine tools for cutting metal machining.
the disc milling cutter
The company was founded in 1930 and
was the reduction in cy-
is known today for its machining centers,
cle time, as only one cut
is needed. On top of that,
special-purpose machines and
the tool only occupies production modules.
Schematic representation one row of spindles, re-
of a production module ducing the resulting tool
further information: www.mapal.com
[image provided by ELHA] costs for the end customer.

no. 3, September 2020 7

materials & tools

Challenging machining process

Fast process for Ni-based alloys

Ni-based alloys -
they withstand high
thermal and mecha­
nical loads, are ex-
tremely corrosion-­
resistant and are suit-
able for many possi-
ble applications. The
other side of the coin:
the machining pro-
cess for these super al-
loys is extremely chal­
lenging. Fortu­nate­­ly,
there is now the
MonsterMill NCR end
mill from CERATIZIT,
which is more than a
match for these mate-
rials.

Whether in the aerospace

sector, the chemical indus-
try or in energy technolo­ The MonsterMill NCR’s above-average tool life and high process security
gy - components made when machining Ni-based alloys is impressive
from Ni-based alloys are
often used wherever high
thermal and mechani-
cal loads prevail. The special properties of these materials Ultra-modern coating technology
speak for themselves: they have excellent heat-resistance, Last but not least, there is also the innovative DRAGON-
are tremendously hard even at high temperatures and on SKIN coating to thank for the MonsterMill NCR’s excel-
top of that, are also extremely corrosion-resistant. At the lent ability to resist abrasive Ni-based alloys. The coating is
same time, these are the properties that often push ma- also a new development and has excellent heat stability, as
chinists and tools to their limits. Manufacturing facilities well as tremendous wear resistance. Protected in this way,
that use state-of-the-art machining processes can only re- the MonsterMill NCR enjoys remarkably long machining
main process-secure and efficient by using tools that have times in a material that is feared by machinists because of
been specially designed for this application. its tensile strength and exceptional hardness.

A perfectly adapted end mill Reliable and efficient

The MonsterMill NCR from CERATIZIT is one such tool.
The milling cutter was specifically developed to take the
unpredictability out of working with this hard and high
tensile material. Various factors ensure that the difficul-
ties associated with machining Inconel® and similar ma-
terials are a thing of the past. The MonsterMill NCR has a
special tool geometry that is precisely tailored to machin-
ing Ni-based alloys. This is crucial, especially in relation to
tool wear, and ensures stable and reliable processes. The re-
inforced core diameter and increasing tapered core effec-
tively counteract tool wear as well, making it possible to
achieve an impressive tool life.
CERATIZIT introduced the MonsterMill NCR in response
to the special requirements of machining Ni-based al-
loys. Having mastered this most challenging discipline,
the NCR enjoys an impressive and above-average tool life
and demonstrates maximum process security. Manufactur-
ing companies where these materials have to be machined
reliably and efficiently cannot do without a milling cutter
like this.
The MonsterMill NCR is one of the highlights in
CERATIZIT’s new Up2Date supplementary catalogue, and is
available from stock since May 2020.

further information: www.cuttingtools.ceratizit.com/gb/en/ncr

8 no. 3, September 2020


Reliable fine machining of steel materials
Getting chips under control
To ensure reliable chip breaking, MAPAL has
developed a new chip guiding stage for machin-
ing steel. After all, if long chips are produced dur-
ing fine machining using tools with guide pads,
this can have negative effects on surface quality,
dimensional accuracy and an automated process
flow. The long chips wrapping themselves around
the tool can cause damage.
The new chip guiding stage combats these very problems.
Its special geometry, which has been designed and opti-
mised with the aid of extensive FEM analyses and practi-
cal testing, means that the chips are broken reliably and
automated workflows are not disrupted. The chip guiding
stage is compatible with all indexable inserts with AS leads
as well as with all coatings. That means that it can be inte-
grated in the relevant insert irrespective of the application
in question, thereby producing process reliability.
The new chip guiding stage ensures reliable chip breaking
in fine machining of steel materials
MAPAL is combining the technical properties of an arc shaped land with the economic advantages of pressed inserts
materials & tools
Machining deep bores without vibration
using indexable inserts
During boring processes with large depths or unstable ma-
chining conditions, vibration often occurs. This vibration
degrades the quality of the bore and has a negative effect
on the life of the tool.
MAPAL indexable inserts with arc shaped land have
proven successful at eliminating this vibration. Very good
results are obtained especially during the machining of
cast materials. MAPAL is now combining the technical
properties of an arc shaped land with the economic advan-
tages of pressed inserts. The result is a highly cost-effective
solution for boring processes with replaceable inserts.
Indexable inserts with arc shaped land are used, for ex-
ample, for cylinder bores, during the machining of crank-
shaft bearing journals, hydraulic housings or also gear­
boxes for wind energy converters. The arc shaped land is
in contact with the bore wall during the machining pro-
cess and supports the tool. This support surface minimises
the vibration that occurs. The arc shaped land is compar­
able with the arc land chamfer on a reaming tool.
further information: www.mapal.com
no. 3, September 2020 9
materials & tools

DTM milling system for brilliant-finish machining

Horn is expanding the DTM face milling

system with inserts for brilliant-finish machining
of non-ferrous metals and plastics.

The DTS type inserts, which are tipped with monocrys-

talline diamond (MCD), make it possible to mill virtual-
ly perfect surfaces and achieve flatness of less than one
µm. The milling system is used in situations where the
surface quality has to meet stringent requirements - in
the case of a mirror finish, for example. DTS type inserts
are tailored to the DTM face milling system and achieve
high levels of efficiency and cost-effectiveness in conjunc-
tion with pre-machining inserts. Either PCD or CVD-D is
used for pre-machining, depending on the material be-
ing processed. All tools for brilliant-finish machining are
generally designed with single cutting edges. The remain-
ing insert seats contain roughing or balancing inserts. The
MCD-tipped cutting edge is set to an axial projection of
0.02 mm. Due to the structural design, the PCD-tipped DTS type inserts, which are tipped with monocrystalline diamond,
roughing inserts always pre-cut radially. This means it is make it possible to mill virtually perfect surfaces
virtually impossible for the MCD insert to be overloaded and achieve flatness of less than one µm
or damaged.

can be adjusted with micrometre pre-

cision. The internal coolant supply
ensures targeted cooling of the con-
tact zone and enables efficient chip re-
moval. The low mass of the alumini-
um body protects the spindle and re-
duces energy consumption compared
with steel bodies. Horn offers a fine
balancing option for the body in order
to achieve high cutting speeds of up to
5,000 m/min and ensures that the tool
runs quietly.

The range of applications for bril-

DTS type inserts are tailored to the DTM face milling system
The insert seats of the DTM milling body can be adjusted
in the axial direction via an adjusting screw. Every ten-de-
gree rotation moves the insert seat by 0.01 mm. This means
that the axial run-out of the individual cutting edges
liant-finish milling is huge. In the tool
and mould making industry in partic-
ular, the method saves polishing while
also increasing the quality of the sur-
face and its flatness. It is therefore
used in applications where the surface
of the mould has a direct influence
on the parts being produced. This in-
cludes, for example, clear, transparent
plastics or valve plate sealing surfaces.
MCD-tipped ball nose end mills are used to produce PET
blow moulds or chocolate moulds. In addition to brilliant-
finish milling, Horn’s tool port­folio also includes solutions
for brilliant-finish turning with MCD tools.

further information: www.phorn.de

10 no. 3, September 2020

 materials & tools

Efficient machining of titanium

Horn is optimising its DS mill-

ing system to enable productive, cost-
effective machining of titanium and
titanium alloys.

The optimisations are made possible by the

newly developed substrate IG3I. By combin-
ing the novel carbide grade with a newcoat-
ing, the tool specialist has been able to in-
crease tool life significantly. Furthermore,
the new substrate demonstrates homoge-
neous wear. A sharp micro-geometry on
the cutting edges, positive rake angles, large
clearance angles and polished flutes prevent
strain hardening of the workpiece and built-
up edges on the rake faces when machining
titanium. Variable helix angles and different
tooth pitches ensure a quiet, low-vibration
milling process. Despite the sharp cutting
edges, the new coating demonstrates very
high layer adhesion, thus ensuring good cut-
ting edge stability. Thanks to its high tem-
perature resistance, the coating serves as a
heat shield and reduces the amount of heat
transferred to the carbide.

In future, the IG3I substrate will replace the By combining the new IG3I carbide grade with a newly developed coating,
previous substrate TSTK, which is already Horn has been able to increase tool life significantly

known on the market for

its high performance. The
end mills are available
in dia­ meters from 2 to
20  mm as standard, with
four or five flutes. The ef-
fective length is two or
three times the diameter.
DS titanium milling cut-
ters were developed based
on the tried-and-tested
solid carbide milling cut-
ters in the DS system,
which for years have
been used to machine
soft and hardened steels,
chromium-­nickel steels
and superalloys as well as
copper, aluminium, plas-
tics and fibre-reinforced
The end mills are available in diameters from 2  to 20 mm, with four or five flutes plastics.

further information: www.phorn.de

no. 3, September 2020 11

materials & tools
PCD- and CBN-tipped
engraving tools…
…for the stamping technology sector, the pack-
aging and printing industry. This is another prod-
uct from LACH DIAMANT Germany - highly
precise and wear-resistant.
Engraving tools tipped with PCD or CBN cutting materi-
als enables competitive machining strategies of process-
ing magnetic flexible dies as well as cutting rotors made of
high-quality challenging materials. Other applications are
for example scoring of PCB (electronic industry) as well as
engraving of high-tensile and wear-resistant materials.
LACH DIAMANT offers PCD- and CBN-tipped engrav-
ing tools in standard or customized dimensions as semi-
finished or finished (incl. side-cut) with highest reachable
surface qualities Made in Germany.
Expansion of the MFH high-feed
milling cutter series
Kyocera has added the new PR015S
MEGACOAT HARD insert grade for stable machin-
ing of hardened materials to its MFH high feed
cutter series. In combination with the likewise
new GH Chipbreaker, it is ideal for a wide range
of applications and especially for difficult milling
operations. Both extensions are integrated into
the MFH Harrier and MFH Mini series.
Different versions of the GH Chipbreaker
12 no. 3, September 2020
engraving of flexible die
example of engraving tools
scoring of PCB
further information: www.lach-diamant.de
Convex cutting edge design for
low cutting forces
The GH Chipbreaker has a convex and very robust cutting-
edge design, so that cutting forces are reduced when en-
tering the workpiece. The high-feed tool also has excellent
breaking resistance. Along with the PR015S insert grade,
the new chipbreaker is suitable for stable machining of
hardened material. The PR015S is characterized by its high
hardness and extremely heat-resistant PVD coating MEGA-
COAT HARD, which improves wear resistance. The combi-
nation of the GH Chipbreaker and the PR015S also reduces
heat cracks and increases the breaking strength of the in-
sert. Different geometries offer the right solution for the
high precision technology industry with a maximum cut-
ting depth of up to 5 mm.
Kyocera responds to high market demand
with MFH expansion
Since its introduction in 2014, Kyocera has continuously
expanded its range of state-of-the-art MFH cutting tools.
This range now includes diameters from 8 to 160 mm. All
inserts in the series feature a convex, spiral edge design,
making them ideal for various shoulder, ramp, slot,
plunge, helix and face milling applications. The MFH was
Kyocera’s first high-feed milling tool and completes the
comprehensive line of cutting tools to meet various manu-
facturing challenges.
further information: www.kyocera.co.uk
 10 - 13 November - Messe Augsburg, Germany
Hall 4, Stand 4088
materials & tools

Re-sharpening service for PCD tools

Efficiency concept for high performance machining tools

Now of all times, a reliable and fast service

is needed to minimise costs - resources must be
saved, and inventories must be kept as manage-
able as possible.

With its headquarter in Hanau, Germany and produc-

tion sites near Chemnitz, Germany and in Michigan, USA,
LACH DIAMANT has extensive know-how regarding de-
velopment, production, and application of polycrystalline
diamond tools since 1973.

Today, state-of-the-art production and re-sharpening ser-

vices allow LACH DIAMANT to further optimise proven
tool designs and geometries for every application which
subsequently results in increased durability, better surface Inspection of a PCD monoblock milling cutter at the
quality and higher feed rates. LACH DIAMANT facility in Lichtenau near Chemnitz

LACH DIAMANT, diamond pioneer since 1922, also pro-
vides this expertise for products from other manufacturers.
The service concept includes all machining tools such as
PCD-tipped inserts, end mills, monoblock milling cutters,
drilling tools, reamers and similar tools; the offer includes
CBN, CVD or mono-natural diamond-tipped inserts and
mill­ing tools. LACH DIAMANT emphasises that this ser-
vice offer also includes repair and/or re-tipping of tools and
saws. It is the top priority to make the use of high perfor-
mance tools more cost efficient, also by way of service.

further information: www.lach-diamant.de

Universal NGU chipbreaker for positive insert

geometries
The versatility and reliability of cutting tools
is becoming increasingly important not only for
turning of components for the automotive indus-
try, but also in many other areas of application.

As a solution to these increasing demands, Sumitomo has

developed the general-purpose NGU chipbreaker for posi­
tive M-class inserts. As already known from negative in-
sert shapes, the positive NGU type also features extremely
stable chip control and covers a very wide range of applica-
tions from finishing to light interrupted cutting.

Excellent chip control despite

different cutting conditions
The chipbreaker shape is characterized by a wide chip
pocket, which provides improved chip control under dif-
ferent cutting conditions. This prevents the chips from be-
ing trapped during the machining process and ensures a
stable process flow. The new chipbreaker geometry is avail-
able for use in both steel materials and stainless steels.
Low cutting forces reduce vibrations
The chipbreaker design provides excellent chip control and
is designed to reduce cutting forces and vibrations during
machining. This reduces cutting edge stress and ensures
a stable machining process in various applications and
cutting conditions.
Improved fracture resistance
for lower machining costs
The multi-stage chip breaker ensures excellent sharpness
and toughness, which significantly improves cutting edge
stability. As a result, NGU chipbreaker reduces the fre­
quency of tool changes and reduces machining costs.

further information: www.sumitomotool.com

14 no. 3, September 2020

 materials & tools

A fresh take on inside deburring

Welded pipes with a longitudinal seam are fre-

quently used for complex applications in different
industries, for instance, the automotive or petro-
leum industry. To fulfil the complex requirements
with regard to tensile strength and dimensional
tolerance, the welding burr is often removed at
the pipe production stage. The new Boehlerit
internal scraper rings constitute the perfect
solution for the clean and efficient deburring of
welded pipes.

The Boehlerit internal scraper rings offer a range of bene-

fits, guaranteeing economic efficiency, precision and out-
standing performance throughout. The internal deburring
tool is suitable for multiple uses due to its adjustable blade.
It also comes with an optimised cutting geometry and
top-of-the-range coating for extended tool life and tight
dimensional tolerances on the finished pipe.

The Boehlerit internal scraper rings are compatible with

the most frequently found tool systems for cutting rings
on the market and with the standard dimensions for pipes Boehlerit internal scraper rings
with a diameter from 12 - 130 mm (cutting ring diame-
ter of 6 - 50 mm), all available ex-warehouse. In addition,
Boehlerit, in cooperation with Ernst Blissenbach GmbH,
offers mechanical scarfers for the removal of internal weld- ideally complement the Boehlerit tool systems for the
ing beads, with or without integrated notching wheels, as machining of welding seams, threads and pipe ends as
well as other internal deburring tools for pipes. All of them well as the deburring of welding beads.

further information: www.boehlerit.com

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materials & tools

LACH DIAMANT looks back on 98 years - 5th part

Poly - poly - or what?

Diamonds show profile

Horst Lach, managing direc-
tor and CEO of LACH DIAMANT
agreed to write an ongoing series
of articles about the develop-
ment of diamond and CBN tools
and grinding wheels in modern
industries.
Horst Lach is known as a true
industry veteran, and we are ex-
cited to have this pioneer of tech-
nology share some insights from
over 59 years of professional
experience in the diamond tool
business.
In this fifth part of this (almost)
historical review, Horst Lach
looks back to the time when dia-
monds first showed profile.
Mr. Denker continued: “We are hav-
ing a problem - can you build a profile
milling cutter for us?” Immediately
I was wide awake. Only 14 days ago, I
would have answered with “no, sorry”,
but now? Most likely I answered with
a drawn-out “yes!” and requested more
details. And so, Mr. Denker contin-
ued: “We call it an american mill-
ing cutter with a profile for a post-
forming work plate with a cutting
width of 45 mm and cutter diameter
of 160 mm.” (All checked, and today
still shown in old documents at LACH
DIAMANT). When the cutter dimen-
sions were mentioned, my reply was
“BUT - unfortunately our production
is not yet ready for this size”. Denker:
“It doesn’t matter, we are sending you
two Leuco milling cutters with car-
bide blades, and you simply take those
off and solder on your diamonds.”
The conversation went that easy -
however, it was pivotal for the future
of this cutting material which was
still in an early development phase,
for us as tool manufacturer and user,
as well as for manufacturers of super
abrasives, such as, at that time, General
Electric with its products “com-
pax” and “BZN” or DeBeers, another
manu­facturer which appeared on the
market at the end of 1968/69, with its
product “Syndite”.
On the following morning, Günter
Hobohm picked up the two carbide

It is 1978 - on October the 13th, my

discovery at the former Matra com-
pany in Frankfurt, that polycrystal-
line diamond (PCD) can be eroded by
means of electric sparks, was registered
at the patents office (see hpt 2020, #2).

In October of 2020 we therefore

will be looking back at 42 years of ex-
perience in the application and use of
spark erosion for manufacturing and
versatile applications with poly­ crys­
tal­­
line blades of PCD/PCBn-tipped
tools.

But back to October of the year

1978. Only a few days had passed
since registering the patent. “Forced”
to maintain silence, the team around
R&D staff members Dipl. Ing. Günter
Hobohm, Gerhard Mai and Konrad
Wagner (†) had not yet been able to
think a lot about applying this tech-
nology. Fortuity became our “ac-
complice” - with a telephone call. A
Mr. Denker of the company Resopal
Werk H. Römmler GmbH in Großum-
stadt (today known as Resopal GmbH)
answered. “Mr. Lach, I read that you
presented milling tools at a trade show
(he was referring to productronica 1977 LIGNA 1979 - a complete diamond tool program for all wooden and plastic materials
in Munich).” I confirmed this. is presented, using the example of a diamond profile milling cutter

16 no. 3, September 2020


milling cutters. Now the carbide cut-
ting edges were removed, cleaned,
diamonds attached, cutting width
45 mm - oh gosh - there was a prob-
lem. The largest insert blanks at the
time, offered by the manufacturer
General Electric, only had a diame-
ter of 13.2 mm. We decided on a semi-
circle cut (GE-Art.-No. 1625), so that
a blade length of max. 13.2 mm was
available.
We had to add pieces. The inserts
were only 13.2 mm long and had to
be soldered on in an overlapping way,
tooth by tooth, to avoid scoring marks
during the following milling process.
Manufactured in this way, the world-
wide first PCD cutting tool for ma-
chining wood materials (postforming
- coated as kitchen cabinet plate) was
manufactured as Z = 4, but due to the
necessary overlapping this diamond
milling cutter really was a Z-2 tool.
Now, regarding the profile. As I re-
member, a classic postforming pro-
file for decorative kitchen plates, only
differing from the “german standard”
- for plate sizes of 45 mm - probably
also called “american milling cutter”
for that reason.
... and now, only profiling -
done!
Being an attentive reader, possibly an
expert, you are right. At the time, this
was not as easy. “Soldering” for exam-
ple. Already the first diamond tool for
milling on a double-end-tenoner was
a monoblock tool - resulting from the
carbide tool bodies given to us - thus
no cassette tool. Again, another coin-
Schematic representation of the first diamond profile milling cutter
with semi-circle overlapping blades
materials & tools
cidence, or let’s rather call
it a stroke of luck, since the
PCD cutting edge, starting
with the very first milling
cutter, were already pre-
pared for the long tool life
of the future, compared to
all other materials.
Ultimately, profiling pre-
pared PCD cutting edges
was “child’s play” (for us),
because the company Matra
did that on a Fanuc wire LACH DIAMANT dreboform® profile milling cutter
machine. For this reason, for coated decorative plates
we are still very grateful
to Mr. Schreiber and Mr.
Becker (compare hpt 2020,
#2). After LACH DIAMANT agreed to Before we went back home to Hanau,
manufacture diamond profile milling we asked “what do you think, how
cutters for the first “wood customer”, long will they be running?“ We could
we had to answer questions, dozens of have expected the answer. “You are
times, on the part of Resopal during the specialists - a carbide milling cut-
the development and manufacturing ter holds approximately three to four
time between Octo­ber of 1978 til Jan- hours, then it has to be resharpened.
uary 1979. “Yes, when can we start - We work three shifts. Therefore, dia-
customers demanding - or can you ac- monds must hold up a bit longer - at
tually do this?“ Finally, on January 5, least a week ...“ We only nodded to
1979, we could report success. Günter that, and said our goodbyes, prom-
Hobohm and I took the opportunity ising to get back in touch within a
and personally delivered the two first­- week.
lings to then watch the first use. I
don’t necessarily want to say that we Top Secret
were shocked when we saw the big The discovery that polycrystalline
“monster” of a postforming system - a dia­ monds could be formed by spark
double-end tenoner (see foto next page). erosion due to their electric conduc-
But we both were aston­ ished. After tivity was still treated as “top secret”
mounting the cutter, the system at LACH DIAMANT company - this
started with a loud roar, and a few was kept even from the PCD supplier
thoughts were going through our General Electric; you never know ...!
minds. “What happens now - do the
cutting edges hold up - does the sol- Not to be misunderstood, the co-
dering hold up? “ But all went well! operation with GE (more and more
with the headquarters in Worthing-
ton, Ohio) was increasingly positive,
so that LACH DIAMANT could even
influence the development of GE’s so-
called compaxTM during that time.
For example, regarding the size de-
velopment of the blanks which had
maximal widths of 3.8 mm in the be-
ginning, from manufacturing sizes of
6.4 
mm/8.1  mm leading up to avail-
able blanks with 13.2 mm at the end
of 1978. As from 1975 onward, PCDs
were still scored with circular dia-
mond saws at the carbide bottom by
diamond manufacturers, depending
on the segment/form that was being
produced.
no. 3, September 2020 17
 materials & tools

“they would not have taken this mill-

ing cutter and …“. It is not known
whether anyone at Resopal noticed
our emerging suspicions - however, al-
most as a reaction, we were told in our
next call “we would like another two
diamond milling cutters with profile”.
The firstlings were still on the ma-
chine - for over four weeks now.

“Diamonds show profile”, an example of
an EDGplus spark-eroded PCD blade
A week had passed by now, and we
had not heard anything about our
dia­mond milling cutter. In eager an-
ticipation, we called Resopal, where
a Mr. Essow had joined in as contact
person, besides Mr. Denker.
“No worries, all is well. Your dia-
monds are still running - there is still
no end of the lifetime in sight ...“
So, it is still running. This answer
was repeated week after week. A cer-
tain nervousness began to set in -
Conversation between
father and son
This was also the time when I asked
my father (Jakob Lach and CEO like
me) how we should further deal with
this. I will never forget his answer. “I
am now 85 years old, if you want to
do this, you are welcome to go ahead
and do it…” This really was the start-
ing shot for the foundation of the
dia­mond company “LACH-SPEZIAL-
WERKZEUGE” as limited company,
on February 13, 1979, in the notary’s
office of my friend Gerhard Grossmann
in Frankfurt. Even in hindsight, it was
a good recommendation of my father
to split the LACH DIAMANT compa-
ny, which was more oriented towards
the metalworking industry, from the
newly found “LACH SPECIAL”, with
the aim of winning customers in the
wood and plastics industry. Luck was
a factor as well, since exactly at that
time, the committee of industrial re-
search associations (AIF = Arbeitsge-
meinschaft Industrieller Forschungsver-
einigungen) initiated company specific
supportive measures for helping start-
ups of small and medium-sized busi-
Diamond profile end milling cutter
on a CNC-controlled router
nesses. The project “Diamonds ma-
chining wood and plastics”, started
with the founding of LACH SPEZIAL,
could move ahead…
Employees were hired, first ma-
chines - including a Wire EDM wire
machine - were ordered, R&D work
could begin - and, of course, acquisi-
tion of customers. Who needs LACH-
SPEZIAL tools for all wood materials?
As is well known, today such a
search falls under “marketing”; short
and simplified today one could say
“look on the Internet” - but in 1979?
At least, even back then, we had sup-
plier catalogues such as “wer liefert
was“ and company listings such as
“ABC der deutschen Wirtschaft“ and
we already had trade shows featuring
this material “wood” - LIGNA for ex-
ample - a world trade show for wood
machining; and the craft trade fair
“Holz-Handwerk”. In the meantime,
approximately March 1979, we knew
that the diamond profile cutters, used
for chipboards, coated on both sides,
were still running at Resopal, much
to the delight of LACH SPEZIAL’s first
customer, and no end of their lifetime
was yet in sight at that time.

Since January, the company Röhm

Example of a postforming facility in Darmstadt, had become another

18 no. 3, September 2020


first-time customer, we had provided
a milling cutter with two polycrys-
talline diamond edges as “pre-cutter”
and one natural diamond blade as “af-
ter-cutter” for polishing acrylic glass,
with success. For the Rowenta plant in
Offenbach we constructed a diamond
profile milling cutter Z-4 under the
new trademark “dreboform®” for ma-
chining an abrasive plastic compo-
nent. Only to show a few of the ma-
chining solutions.
“The cat was out of the bag”
Apparently, a successful product,
but where to go with it…? The small
team of “LACH SPECIAL” - my hum-
ble self of course included - was now
already very euphoric. The key word
was “wood”; the crafts trade show, so
I thought as “wood layman”, would be
the place to find potential customers
and inspirations.
I stood in front of a very impressive,
compact and heavy machine, which
gave me hope. It was one of the first
numerically controlled routers, during
the profile milling of a decorative
plate made of MDF (Medium Density
Fibreboard), a router of the company
MAKA. I was able to enthuse the owner
of this company, Mr. Lobedank, by
listing possible lifetimes and sur-
face quality during milling with di-
amond. We quickly agreed that he
would show this “novelty” in action
LIGNA 1979 - with melodious play - the worldwide first presentation
of diamond tools for all wooden and plastic materials
materials & tools
on his new router
as a highlight at the
upcoming LIGNA.
And so, it hap-
pened. A dreboform®
PCD end mill, type
FZ24/20, shaft Ø
12 mm x 20 mm,
with plunge cut, was
used - machining:
veneered chipboard.
CNC router, made
by MAKA. RPM =
1 7. 9 0 0  r e v s / m i n .
Per­formance tested
in prac­tice: 30.000
milling oper­ations;
a max­ imum of 100 Diamond end milling cutter on a CNC-controlled surface
(one hun­ dred) mill- during the machining of multiplex plates
ing operations were
achieved with a
com­­parable carbide tool. Also, a 300 surprised the industry experts with a
times higher lifetime compared to tool program, complete with all un-
carbide. Yes, I can already predict that til then known tools for the wood
lifetimes of diamond tools for ma- and plastic industry - as alternative to
chining wood and plastic materials carbide tools.
will play out at 250 - 300 times higher,
compared with the average possible “The cat was out of the bag”, the
performance of a carbide tool. Many secret about the activities of LACH-­
plus factors for this new technology, SPEZIAL (almost) revealed. But this
and for the start-up company LACH- was only the beginning for the wood
SPEZIAL, as it should finally be seen and plastic processing industry, furni­
at the worldwide first presentation of ture and parquet manufacturing in-
diamond tools for machining wood dustry, automobile and supplier in-
materials and plastics at LIGNA 1979. dustry, aircraft and wind power plant
LACH-SPEZIAL-­W ERKZEUGE GmbH manufacturing, machine and tool in­
dustry in general, and in particu­
lar for the companies LACH-SPEZIAL
and LACH DIAMANT. “Diamonds
show profile” and this already in
1980/81, future-oriented for wood
and plastic machining, as documen­t-
ed in two videos of the first start, cre-
ated by LACH-SPEZIAL-WERKZEUGE
GMBH and available at vimeo.
com/206233393 and
vimeo.com/2062319829.
“Poly - poly - or what?“ - an inexhaustible
subject... to be continued...
Horst Lach
P.S. By the way, the dreboform® dia-
mond profile milling cutters delivered
to Resopal Werk H. Römmler GmbH
on January 5, 1979, came back for
regrinding for the first time on June 1,
1979 - after five months.
further information: www.lach-diamant.de
no. 3, September 2020 19
news & facts companies

Horn Group expands internationally

On 1st April 2020, Horn Group estab-
lished a company in Turkey. It has taken
over sales of the precision tool manufac-
turer’s products in the Republic, a service
that was previously provided by a trading
partner.
Horn took the decision to establish direct repre­
sentation in Turkey so that the needs of existing
and potential customers can be better served. The
motto is: Think globally, act locally. In Turkey the
same objectives are to be pursued as those set by
Horn in Germany and many other countries: tech-
nological advantage for users combined with sus- Horn’s product portfolio offers Bahadir Öge,
tainable customer relations. As each country is comprehensive tooling solutions to meet one of the Managing
unique, there is wide scope regionally to respond to customer requirements in Turkey Directors of Horn Turkey
local conditions. The new sales office is located in
Istanbul and at the outset covers a floor area of
450 m². Bahadir Öge, one of the Managing Directors of Germany), the original plan was for annual growth in real
Horn Turkey: “The country offers excellent growth oppor- gross domestic product of five percent up to 2022. How-
tunities for our products. I am convinced that we will ever, how this will develop in view of the corona crisis re-
achieve our goals in the medium to long term and that we mains open not only in Turkey but also in the global econ-
will also further extend our established position as tech- omy. Nevertheless, Öge is confident and adds: “Especially
nology leader in Turkey.” in the coming period, innovative and targeted tooling
Turkey covers 783,562  km² and had a population of solutions will be needed to improve and optimise cutting
around 83 million in 2019. Although the machine tool processes so that manufacturers can avoid having to invest
business has been declining since 2019, the government’s in a new machine in the short term. "
medium-term outlook was positive. According to the
VDMA (the Mechanical Engineering Industry Association in further information: www.phorn.de

LMT Tools named innovation champion

Innovative medium-sized compa- nal threads, it is partly produced using

nies such as LMT Tools are not afraid
of change, but see it as an opportu­
nity. The company was selected in
the 27th round of the TOP 100 in-
novation award. As of June 19th,
LMT Tools is recognized as a Top
100 company in the categories of
“Innovation-promoting top manage-
ment” and “Innovative processes and
organization”.
The management of the manufacturer of
precision tools has firmly anchored the goal
of innovation leadership in the company.
To keep creating bubbling ideas from which innovations
can be generated, the top innovator relies on a wide range
of methods, field trials with customers, and cooperation
with universities.
The 1,200 employees around the world have been in-
venting new precision tools for more than 100 years, and
are now using 3D technology. Just like with the “EVOline”
tangential rolling head, a tool for manu­ facturing exter-
3D printing. “This smart tool illustrates
our idea of innovation. We develop
new solutions by expanding the limits
of existing technology and thus signifi­
cantly increasing the benefits for our
customers,” says CEO Daniel Ehmans.
The TOP 100 com­ pany would like to
provide smart tools with sensors in
the future so that corresponding digi­
tal data is available - a field with great
innovative potential.
Another building block of the innova-
tion strategy of LMT Tools is the inten-
sive networking amongst the departments. This includes
regular workshops that promote knowledge exchange.
The research and development departments at the various
global locations also exchange information on an ongoing
basis, and the employees have a lot of freedom to come up
with ideas.
further information: www.lmt-tools.com

20 no. 3, September 2020

 fairs news & facts

D-EXPO Metall
Digital trade fair for metalworking
in September 8-10, 2020

The Carl Hanser Verlag invites to the digital trade

fair premiere of the D-EXPO Metall: Companies,
associations and institutions involved in ma-
chining, tool and mould making have the oppor­-
tunity to take part in a virtual industry meeting
from September 8 to 10, 2020. The digital trade
fair will start with three “live days” and will be
available online on the trade fair homepage until
2nd October.
The D-EXPO Metall creates the opportunity to get first-
hand information about important innovations, topics
and trends and to exchange ideas. The digital trade fair
will start with the three “live days” (September 8-10) with
many interactions, live streams and occupied exhibition
stands. In the auditorium, webinars, interviews and lec-
tures on all aspects of metalworking are on the agenda. All Advantages for visitors at a glance:
information will be available on the trade fair homepage Ø new trade fair:
www.d-expo-metall.de until 2nd October. discover innovative products and offers
The multimedia platform offers a networking event for Ø current live event:
the metalworking industry and stands for direct commu- enjoy direct communication with all exhibitors
nication: during the live-event, “everyone can see every- Ø extra duration:
one” and, if desired, can speak directly via chat. The fair is all documents are still available two weeks
free of charge for visitors. after the live event
Exhibitors come from the following sectors: machine Ø informative supporting program:
tools | precision tools | standard parts | coolants | software webinars, lectures, interviews and discussion panels
| industry 4.0 | security technology metrology | automa- Ø simply digital:
tion | additive manufacturing and all topics related to tool convenient and efficient access from home
making and mould making
further information: www.d-expo-metall.de

PaintExpo 2020 cancelled after all

8th world’s leading trade fair for industrial coating technologies

Due to the still fragile corona situation, stricter
hygiene and distancing regulations for trade fairs
in Baden-Württemberg and sustained restrictions
on international travel, PaintExpo 2020 will be
cancelled after all. The next world’s leading trade
fair for industrial coating technology will take
place as scheduled in 2022.
“We now intend to devote all of our energy to prepar-
ing the next regularly scheduled PaintExpo in order to
provide the industry sector with the best possible con-
ditions for successful trade fair participation”, reports
Jürgen Haußmann, managing director of event promot-
ers FairFair GmbH. The next world’s leading trade fair
for industrial coating technology will take place at the
Karlsruhe Exhibition Centre from the 26th through 29th of
April, 2022.
further information: www.paintexpo.de

no. 3, September 2020 21

news & facts
Finally experience grinding technology trends live
The world’s leading trade fair for grinding tech-
nology, GrindTec, will start in autumn as one of
the first important trade fairs. From 10th to 13th
November, 2020, it will offer an important and
necessary platform for the metalworking industry.
The latest figures of the ifo Institute for Economic
Research send positive impulses for this.
During the Corona crisis, the business climate index fell to
a historic low of 74.3 points in spring. Current figures of
the ifo business climate index and evaluations by Statista
are already showing positive trends again: The 9,000 sur-
veyed companies from the manufacturing, service, trade
and construction sectors are confident about the coming
months. Currently, a slight improvement is already evi-
dent after the low (86.2 points) in June. Looking ahead to
the next months, the positive trend is continuing and the
business climate index is expected to rise to 91.4 points.
The interviewees from the manufacturing industry are
looking to the future and are expecting a clear improve-
ment - which has a decisive effect on the current business
climate and sets the course for GrindTec.
Grinding technology sector relies on the
strength of its leading trade fair
Of the approximately 650 exhibitors who had registered
for the March date, almost all were able to confirm the
new date in November. It has already been possible to fill
some of the cancellations with new exhibitors. At pres-
ent around 640 exhibitors are taking part in GrindTec in
November.
22 no. 3, September 2020
fairs
Experience grinding technology trends live
As the leading trade fair for new technologies in grinding,
honing, lapping and polishing, the coming GrindTec will
bring the sector together again after a long time. In the
direct dialogue between visitors and manufacturers, new
perspectives for tool grinding will open up, which can lead
the companies out of the crisis.
Impulses are provided by highly functional solutions and
further developments such as
t hybrid grinding machine concepts that also integrate
other manufacturing technologies
t additive manufactured flow-optimized cooling
lubricant nozzles
t direct drives in the grinding machine axes to
improve dynamic stiffness and accuracy as well
as to increase performance
t new 5-axis machine concepts for tool grinding
t laser processing possibilities of diamond tools or
diamond-coated tools.
The Corona crisis has clearly shown not only to the tool
grinding industry that digitalisation, networking and au-
tomation are indispensable. Many new business models
are currently being created which have enormous econom-
ic potential. Creating added value in production technolo-
gy at the same time in different places in the world is only
possible with a modern network economy. The manufac-
turers of machines and peripheral systems, of process and
tool technology have developed answers to these ques-
tions, which they will present live on site.
further information: www.grindtec.de
 fairs news & facts

Virtual customer day at UCM

Trends, information and the latest process technology
for precision cleaning

In times of contact restrictions, travel

constraints and trade fair cancella-
tions, the virtual customer day held
by the Swiss company UCM AG of-
fers customers and interested parties
a safe way of keeping up to date with
the latest developments in the field of
precision and ultrafine cleaning. Pre-
sentations in German and English
will inform about current trends and
demands, as well as about solutions
and innovative processes for meeting
the requirements set by many indus-
tries for ever-cleaner parts. The inno-
vative UCMSmartLine, which can be
individually configured from stan-
dard modules, will also be showcased
for the first time at the digital exhibi-
tion booth September 29, 2020.

Companies from sectors such as the medical

engineering, optics, automotive and supplier
industries, precision engineering and micro­-
technology, the jewelry, watchmaking and
coating industries, and also high-purity
processing, are confronted with ever-increas­-
ing cleanliness requirements related to par-
ticulate and film-type/chemical contami­ Trends, information, efficient solutions and the innovative and
nation. Solutions to these issues are often highly-adaptable UCMSmartLine for efficient precision and
discussed during a visit to a trade fair, but ultrafine cleaning are the focus of the first virtual customer day
that is not possible this year. In order to in-
form customers, users and other interested
parties on a larger scale and to answer ques-
tions, the Swiss company UCM AG - a divi-
sion of the SBS Ecoclean Group specializing in precision and Recognizing trends and providing
ultrafine cleaning - is staging a unique digital customer optimal solutions
day with a virtual exhibition booth. The presentations with subsequent Q&A rounds also ad-
dress the different and growing demands of the various
World premiere of the highly-adaptable, branches of industry. They will be held in German and
modular UCMSmartLine English with a time delay. Topics include “Customized so-
One of the program highlights of the online event Sep- lutions for precision cleaning”, “UCMSmartLine - modular
tember 29, 2020, will be the first-time presentation of the solutions for ultrafine cleaning”, “Solvent-based processes
novel smart solution for efficient precision and fine clean- for ultrafine cleaning” and “Innovative processes for
ing, UCMSmartLine. The innovative and cost-efficient ul- highest cleanliness requirements”.
trasonic cleaning series is based on standardized modules,
including not only integrated electrical and control tech- The customer day is free of charge. The virtual exhibi-
nologies for the process steps of cleaning, rinsing, dry- tion booth can still be visited after the online event. Ac-
ing, loading and unloading but also a versatile transport cess to the customer day and exhibition booth is available
system. The modules are used to configure customized to participants via
systems for pre-cleaning, intermediate and final cleaning, https://ucm-ag.com/virtual-customer-day/
and can be adapted to changing requirements and market
conditions at any time. further information: www.ecoclean-group.net

no. 3, September 2020 23

processes
Adhesive bonding:
Opportunities for cutting tool manufacturers
written by Michael Stroka, Thomas Götz and Andreas Gebhardt,
Fraunhofer Institute for Manufacturing Engineering and Automation IPA
Today, the German cutting tool industry, pre-
dominantly small and medium-sized enterprises
(SMEs), faces multiple challenges. In order to con-
tinue to meet the customer requirements in terms
of tool performance, sustainability and machin-
ing quality, new technologies must be taken into
account. This helps to maintain market leadership
in the competitive global environment.
To encounter the challenges of producing high quality cut-
ting tools with outstanding performance new technologies
play a key role for the manufacturers. Within the frame-
work of the project “Innovationsforum Zerspanwerkzeuge”,
funded by the Federal Ministry of Education and Research
(BMBF), suitable technologies and innovative solutions for
SMEs were identified by the Fraunhofer Institute for Manu-
facturing Engineering and Automation IPA. Alternative manu­
facturing methods for product and process optimization
have to be considered in research and the development of
new generations of cutting tools.
Various types of cutting tool designs
In the current state of technology, two different tool de-
signs are used to manufacture milling tools. The cutting
tool is on the one hand designed as a solid tool, in which
the cutting part and the shank are machined (e.g. by
grinding) from a monolithic cutting material (see figure 1a).
On the other hand, a multi-part design is applied, in which
figure 1, types of milling tools
a) monolithic construction
b) composite tool with bolted inserts
c) composite tool with brazed inserts [Leuco AG]
24 no. 3, September 2020
the shank is made from a tougher and cheaper base mate-
rial and the cutting edges from a harder, more wear-resis-
tant material (e.g. carbide, CBN). However, the latter pro-
cedure requires the two components to be joined together.
The joint can be produced mechani­ cally by screwing
or clamping (see figure 1b) or in a material-locking man-
ner by soldering (see figure 1c) [Klocke and König 2007]. As
regards end mills, the most common practice for provid-
ing a joint between the cutting edge and the base body is
currently brazing at working temperatures of over 700° C.
How­ever, this restricts the selection of usable cutting ma-
terials. While some cutting materials are not suitable for
a brazing process, others can be permanently damaged by
high thermal stress [Stroka et al. 2018; Tigra GmbH 2018]
such as diamond (PCD), which graphitizes at temperatures
above 730° C [Tigra GmbH 2018]. In addition, high temper-
atures can lead to distortion of the cutting tools [Stroka et
al. 2018].
Low-heat joining through the use of
bonding technology
Structural adhesives offer a competitive alternative to the
established soldering process for the high-strength con-
nection of cutting segments to tool bodies [Brand and
Hustedt 2015; Stroka et al. 2018].
Bonding is a low-heat joining process using an adhesive.
According to DIN 8593-8 (DIN 8593-8:2003-09) adhesives
are non-metal materials which bond assembly parts
by means of surface adhesion (adhesion through
wetting and interlockability) and internal strength
(cohesion through inter-molecular attraction). The
functional principle of the adhesive bond is shown
schematically in figure 2.
A particular advantage of the joining process
is the material independence of the joining part-
ners, so that a large number of material combi-
nations can be bonded with long-term stabili-
ty, such as steel and carbide, PCD/CBN or cutting
ceramics [Brockmann 2008; Luhn et al. 2012a;
Moser et al. 2013]. Moreover, the low-heat joining
process prevents changes in the microstructure and
the formation of microcracks in the cutting mate-
rial [Brockmann 2008]. Further adhesive applications
in cutting tools can take other advantages like vi-
bration dampening, corrosion protection or reduc-
tion of mass inertia due to lightweight construction
[Doobe 2012]. In addition, the reworking costs for
distortion and complex cleaning processes that arise
during brazing are eliminated [Doobe 2012]. Given
 processes

tion and im­ plement process con-

adherend 1
trol have to be taken into consid-
eration when dimensioning the
joint. To perform a high repro-
duction rate of the reachable joint
adhesive power strength automation processes
cohesive power
between adhesive
in the adhesive are necessary. Otherwise, a failure
layer and substrate
layer in the bond could have a fatal im-
surface
pact both on the machine and its
operator. An overview of the advan-
tages and disadvantag­­es of adhesion
technology is presented in table 1.
adherend 2

figure 2
schematic representation of an adhesive bond
[Habenicht 2009] table 1 advantages and disadvantages of adhesion technology
[Habenicht 2009]
the advantages mentioned above, such as the use of new
cutting materials on circular blades (figure 3), the adhesive advantages disadvantages
bonding technology could have a considerable impact on
the cutting tool industry. no thermally conditioned surface preparation
stress of the micro structure of the joining parts
However, the use of adhesives instead of brazing alloys
also brings some disadvantages. The lower ther­ mal sta- no thermally conditioned limited form stability
bility and the high effort to carry out surface prepara- part deformation under thermal loading

figure 3 possibility of joining

accurate process control
different cutting materials on a circular saw blade different materials

high dynamic stability; time influence of the

high vibration dampening whole procedure

Current research in the field of the

adhesive bonding of cutting tools
Individual research projects have been carried out in re-
cent years to prove the usability of adhesives for different
cutting tool applications.

Darwish, for example, investigated the mechanical per-

formance of bonded joints under thermal influence and
the vibration dampening capability of milling tools with
tungsten carbide carbide tips and steel body. Bonded millers showed less
wear, an improved surface roughness of the manufactured
parts and only small differences in cutting forces. [Darwish
and Davies 1989]

Two funded projects in 2003 and 2007 (IGF no. 12792 N

and 15028 N) used adhesives to join diamond-segments on
circular blanks for stone-working applications. They also
investigated optimized joint geometries with finite-ele-
ment methods and developed a partially automated main-
tenance module. Moreover, successful cutting of granite
was carried out. [Stehr et al. 2003; Stehr 2004; N.N. 2010]

Bonded saw bands for stone-working were investigated

in the IGF project no. 17193 N and cutting trials were suc-
cessfully performed. In this context, new joint geometries,
SiAlON-ceramic capable adhesives and surface treatment were taken into
[Fraunhofer IPA, photographer Rainer Bez] account. [Kohl et al. 2014; Kohl et al. 2015; Schwarte 2015]

no. 3, September 2020 25

 processes
The use of ceramics on circular saw blades was investi-
gated at the Graz University of Technology. Here, the in-
crease of the joint strength was identified as the main topic
of operational tools. [Moser et al. 2013]
The results of the IGF project no. 16031 BG proved the
usability of bonded hard materials in metal machining.
This included an extensive trial with adhesives and sur-
face treatments to maximize the joint strength. [Luhn et al.
2012b; Jahn et al. 2012]
Investigations of bonded ceramics for drilling tools were
carried out by GFE e.V.. Here, the best machining results
of carbon fiber reinforced plastics were performed with
SiAlON-ceramic as cutting material. [Reich and Preiß 2015]
The Institute for tool research and materials IFW car-
ried out investigations with composite circular bimetallic
blanks with a plastic or copper layer in between for vibra-
tion stabilization. [Dültgen and Zobel 2014]
Fraunhofer IPA also participates in the research activi-
ties concerning new joining methods for cutting tools and
new approaches to substitute limited resources [Schumpp et
al. 2018]. Circular saw blades with bonded carbides have
shown their ability to cut aluminum in a special intermit-
tent cutting process developed by Fraunhofer IPA [Stroka
et al. 2018]. In a research project, funded by the Feder-
al Ministry for Economic Affairs and Energy (BMWi), the
adhesion technology for the use in circular saw blades
for wood-working and plastics was investigated both by
Fraunhofer IPA and the Institute for tool-research and ma-
terials IFW. Initially, an analysis of the existing cutting
forces and temperatures with conventional circular saw
shear strength τ / MPa
T10MG T10MG UC KCR05+ KCR05+ KCR32 KCR32
blasted blasted degreased blasted degreased blasted
cutting material and surface treatment
figure 4
joint strengths with different cutting materials
and surface pre-treatments
[Stroka and Keßler 2020]
26 no. 3, September 2020
blades was conducted to gain knowledge of the load in
the joint. The mechanical load was transferred to virtual
models to analyze and optimize the joint geometry with
finite element analysis in reference to the requirements
of the adhesion technology. Simultaneous investigations
of adhesives revealed different strengths of the joints de-
pending on the adhesives and surface pre-treatments. In
figure 4, different joint strengths of variable parameter sets
are shown. Comparable brazed joints showed an average
strength of 146,6 MPa. [Stroka and Keßler 2020]
Fully carbide-tipped circular saw blades have been pro-
duced and grinding and sawing processes were performed.
Individual bonded joints of the saw teeth could not handle
the grinding forces and temperatures. The adhesive failed
due to weak positioning which led to excessive loads and
unwanted load cases like peel stress because of the manual
joining process. Hence, an automation concept was de-
veloped. A conventional brazing machine for circular saw
blades served as foundation. Initial tests have shown im-
proved accuracy and the inductive hardening of the adhe-
sive worked well. [Stroka and Keßler 2020]
Future challenges for a successful implementation
of the adhesive bonding technology
Future research has to aim at a reliable industrial joining
process, comparable to the brazing processes for the indi-
vidual cutting tools today. Without full automation, the
technical and economic goals of creating customer attrac-
tive products cannot be achieved. A big variety of surface
treatment methods, adhesives and hardening processes are
state of the art. Here, the main challenge lies in the right
selection and implementation in the manufacturing pro-
cess. A detailed view at the temperature surveillance, if
infrared pyrometers are still used, is necessary because of
the variable emissivity of the components.
The identification of a better shape than the usual joint
supports the bonding performance and has to be consid-
ered in the development process for new cutting tools for
special applications. Depending on the mechanical and
thermal stress in the joint, optimized joint geometries
have to be developed.
Conclusion
The examples in this paper show the utilizability of the ad-
hesion technology in the cutting tool industry. Over the
last decades, intensive research has delivered good results
because of improved adhesives, especially under thermal
load. Automatic joining processes and machines will help
to establish adhesively bonded cutting tools for special
applications. The new cutting tools can draw advantage
from the possibilities given by the adhesives in terms of
vibration dampening and use of new cutting materials.
Acknowledgment
The authors would like to thank both the Federal Ministry
of Education and Research for funding the “Innovations-
forum Zerspanwerkzeuge” and the Federal Ministry of Eco-
nomic Affairs and Energy for funding the Aif IGF-project
no. 19446 N.

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Kleben. Grundlagen, Technologien, Anwendungen
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no. 3, September 2020 27
processes

FT gearing count on Studer Grinders -

the count is now 16!
Customer wishes are taken into account

Quality has been described as an on-going pro-

cess of building and sustaining relationships by
assessing, anticipating and fulfilling stated and
or implied needs. Never has this definition been
more appropriate than when applied to Aldershot
based FT Gearing Systems Ltd. In addition to
establishing long-term relationships with its
customers, the renowned manufacturer of gear
technology and high-precision components also
enjoys enduring associations with a small number
of carefully chosen machine tool suppliers.

Since the company’s inception in 1978, to ensure the effi-

ciency and premium quality of its output, and to further
expand its range of proficiencies, the business has pursued
a policy of regularly investing in the best available manu­
facturing technologies. This prudent strategy has helped
FT Gearing to earn an excellent international reputation
and enabled it to broaden its customer base. In addition
to its principle, global aerospace and defence industry cus-
tomer base, FT Gearing now serves an increasing variety
of businesses across several equally challenging, diverse
industrial sectors.
To further improve production efficiencies, the business
has established five satellite production units that are co-
located to its Impressive HQ. Each facility is dedicated to
a separate manufacturing function. FT Gearing Systems’
most recently opened production unit specialises in high-
precision grinding. The advanced, temperature controlled
facility houses the company’s 16 Studer CNC Grinders.

When involved in the production of premium quality Explaining the company’s loyalty to the Studer brand
gear technology and high precision components, two of and the reasons for the new Grinding facility, FT Gear-
the most important technical prerequisites are, the ability ing Systems’ Managing Director Graham Fitzgerald said: “In
to achieve demanding dimen­
sional tolerances and to impart
the required surface finish char-
acteristics to workpieces. To en-
sure that FT Gearing Systems
consistently delivers in each of
these challenging areas, and
to maintain maximum lev-
els of efficiency, the company
has developed close relation-
ships with the Swiss Grinding
Machine manufacturer Studer
and the company’s UK agent,
Advanced Grinding Supplies Ltd.

Over several years, FT Gearing

Systems’ continuous expan-
sion has led to regular addi­ -
tional investments in the
Swiss machines, resulting in
the company now operating
16 Studer CNC Grinders - the
largest collection of Studer
Grinders owned by a single
UK company.

28 no. 3, September 2020

 processes

addition to other challenging custom-

ers, we manufacture and supply both
domestic and overseas defence and aero-
space companies with a wide range of
safety critical components, such as gears,
miniature gearboxes, fuel pumps, en-
gine controls, wing surface actuators and
instrumentation.”

“Given the sectors we deal with, qual-

ity is in the very DNA of FT Gearing
Systems and permeates every aspect of
our work. A major part of our quality phi-
losophy is to provide our highly skilled
staff with the best available machine
tools and to maintain close relationships
with our machine tools suppliers.”

“A perfect example of our use of pre-

mium quality production aids is our use
of our range of advanced Studer CNC
Grinders. These technically superior ma-
chines are able to consistently deliver
levels of accuracy and repeatability that
conventional grinding machines are
unable to achieve. For instance, through
the use of Studer technology we are able
to accomplish sub-micron total cylindric-
ity results on 35 mm diameter gear jour-
nals, we can also achieve 0.08 um levels
of surface finish and gear flatness to three
light bands.”

“To enable grinding to sub-micron

dimensional tolerances we recently in-
stalled our Studer CNC machines in a
new, temperature controlled grinding
facility. To guarantee the highest possible levels of quali-
ty and productivity, we also use the best available grind-
ing consumables and accessories. Therefore, as well as
purchasing our Studer Grinders from Advanced Grinding
Supplies, we also rely on the company for items such as
Diamond Dressing Tools, Precision Centers, Abrasives/
Grinding Wheels, Coolant Filter Media and Air Filtration
Systems.”
“Our Studer CNC Grinders provide excellent levels of
precision, surface finish and reliability, they also deliv-
er outstanding levels of production. Even though we have
always been delighted with the performance of our
Studer machines, mindful of the possibility of techni-
cal developments made by other manufacturers, in the
past we have considered other brands. Although, each
time we have been able to specify a Studer Grinder
that perfectly meets our needs and that outperforms the
alternatives.”
The Swiss business, Fritz Studer AG was established in
1912. Now an acknowledged leader in its chosen sector,
the company manufactures premium quality grinding
machines for the internal and external cylindrical grind-
ing of small and medium sized work pieces. Studer’s core
strength lies in the production of machines for the effi-
cient grinding of single, small and medium sized produc-
tion runs.
Peter Harding of Advanced Grinding Supplies concluded.
“As exclusive sales agents for Studer Grinding Machines in
the South of England and in South Wales, we have estab-
lished a strong working relationship with FT Gearing. In
cooperation with FT Gearing Systems’ Managing Director
Graham Fitzgerald, I have been pleased to assist in spec-
ifying each new Studer machine so that it exactly meets
FT Gearings demanding needs.”
“In addition to the staff of Advanced Grinding Supplies
being available to offer technical assistance to FT Gearing
Systems, we also provide the business with a full range of
additional equipment. These consumables, including tool-
ing, help the company to maximise the performance its
Studer Grinders.”

further information: www.studer.com

no. 3, September 2020 29

processes

Brilliant performance in countersinking

in CFRP, GFRP and composites
In order to reduce weight while maintaining Therefore, it was
high strength in complex components, lightweight important to main­-
materials such as CFRP, GFRP and CFRP-titanium/ tain the extreme-
CFRP-aluminum stacks have become in­ dis­pens­ ly sharp cutting
able in the construction of automobiles, aircrafts, edges during coat-
wind turbines and sporting equipment. However, ing. “The ultra-
machining them is no easy task. Anyone wishing thin coating speci­
to perform precise countersinking in sandwiched fication based on
materials with high surface qua­ li­
ties will need CCDia®­­­Aero­­Speed® The countersink with the customized
special tools such as the CCDia®AeroSpeed® coated has no influence CCDia®AeroSpeed® coating ensures
countersink from Dürr Präzisionswerkzeuge GmbH. on the micro­ geo­ smooth countersink surfaces
me­ try and, there­
“Composites consist of several layers. The individual mate- fore, does not affect
rials exhibit different properties and are often highly abra- the sharpness either,” states Marco Furrer. The extremely
sive. Protruding fibers and delamination must be avoided smooth surface topography of the coating allows the coun-
at all costs, as components with these defects end up on tersinks to operate without vibrations or chat­ter, and this
the reject pile. With countersinking, the fact that the tool optimizes the removal of swarf and heat from the machin-
penetrates the material with its an- ing zone. With a coating hardness of
gular cutting edges quickly causes approximately 10,000 HV0.05 - near-
tool vibrations that result in chat- ly that of natural diamond - the tool
ter marks in the countersink,” says also provides out­standing resistance
Wilhelm Marx, CEO and Production to the very strong, highly abrasive
Manager at Dürr, outlining the chal- fibers.
lenges of CFRP machining.
An inspiring result
Dürr Präzisionswerkzeuge GmbH, The DIAplus countersink is the
founded in Hohenlohe in 1994, is an result of intensive cooperation - the
expert in the manufacture of drill- perfect combination of optimized
ing, countersinking and reaming The CCDia®AeroSpeed® coating cutting geometry, a selected grade of
tools for a wide range of materials, specification facilitates the long service life carbide and a customized diamond
in standard and customized designs. of the DIAplus countersink when coating.
With the innovative ENORM plus machining composite materials
countersink for machining wear-re- “Countersinking in composites and
sistant and structural steels with tensile strengths of up to stacks was previously considered a major challenge. The
1750 N/mm2, the company has successfully established it- symbiosis of our countersink and the customized CCDia®­­­
self on the market as a problem solver. In order to master Aero­­Speed® coating now ensures brilliant performance
the challenges of developing a countersink for machining in the machining of GFRP and CFRP as well as CFRP-
composite materials, the company first brought the know- titanium and CFRP-aluminum stacks. The service life of
how of CemeCon’s coating experts on board. the tools is disproportionately long, and DIAplus guar-
antees almost unrivaled process reliability for machining
Perfectly tailored coating and geometry tasks. Countersinking in installed components can even be
“Wear-resistant tools with extremely smooth, hard surfaces done with hand-held machines under difficult operating
and special geometries with very sharp cutting edges were conditions,” enthuses Wilhelm Marx.
required. As part of our Premium Plus Service, we ap-
proached the optimum solution with a targeted variation Uwe Späth, CEO and Sales Manager at Dürr, is pleased
of several factors for both the tool and the coating,” says with the large volume of positive feedback from users:
Marco Furrer, Sales Manager at CemeCon. “Satisfied customers are our top priority; firmly convinced
users are important to us. With the DIAplus, we have
During the cooperation, Dürr further developed its tried achieved this brilliantly and have been able to prove our
and tested cutting geometry to meet the special require- status as a solution provider yet again. Last but not least,
ments of CFRP machining. “The customized geometry pre- thanks to our intensive cooperation with CemeCon, we
vents delamination and cuts the fibers of the laminates now offer lightweight construction a perfect solution for
very accurately throughout the entire countersink area. countersinking in composites.”
This yields countersinks with smooth surfaces - with no
further information: www.cemecon.de
objectionable fiber protrusions,” says Wilhelm Marx.

30 no. 3, September 2020

 processes

International research institutes invest in

3D metal printing machines
A growing number of university institutes chine will play a key
and private research companies are investing in role in the new OMIC
GEFERTEC machines for innovative 3D met- Center focused on ad-
al printing. 3DMP® is being used to test new ditive manufacturing.
manufacturing techniques and the processing of This new center will
different metals. provide a critical op-
portunity to develop
Together with the EMAG subsidiary in China, GEFERTEC research in rapid tool-
is now serving a new customer in the research sector. ing that is critical to
Nanjing University of Aeronautics and Astronautics, in co- some of OMIC R&D’s
operation with its joint venture partner Pukou Advanced largest members, in-
Manufacturing Research Institute, has purchased a GEFERTEC cluding Daimler Trucks
arc405 machine for aerospace research projects. The uni- North America, LLC.
versity has its own subsidiary and is involved in techno­ GEFERTEC, through
logy transfer for this important future industry. its OMIC R&D mem- A joint venture between Nanjing
bership, will maintain University of Aeronautics and
A GEFERTEC arc605 is being installed at the Oregon Man- close contact with Astronautics and the Pukou Advanced
ufacturing Innovation Center (OMIC) on the west coast of the these members and Manufacturing Research Institute
USA. As a joint research facility, the OMIC R&D is spon- with potential users of purchased an arc405 for
sored by 29 industrial companies, three academic institu- the arc605. aerospace research projects
tions and the state of Oregon. The center supports mem-
further information: www.gefertec.de
bers with joint manufacturing projects. The arc605 ma-

Sawtec 2.0 –
Saws with
interchangeable teeth
■ Easy and quick exchange of the
screw-mounted carbide saw teeth
■ The patented „SawLock®“ clamping system
ensures stability, efficiency, precision and a
high degree of flexibility
■ The interchangeable teeth come with a
state-of-the-art coating: Increases the
cutting surfaces by up to 200 % in m2,
while increasing the cutting speed at the
same time
■ Ideal blade for steel, stainless steel and
highly heat-resistant steel selectable
■ Interchangeable teeth with a width of
9 mm - Saw blades are available in a
diameter range of 600 to 1500 mm
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Robot cell increases productivity by 30 %

The specialty of Kern Microtechnik GmbH in range around the

Germany are highly complex and precise parts. clock. No staff is
To further increase quality and productivity Kern needed for night- or
also puts a focus on innovative automation. For weekend shifts, the
example, one robot cell with four Kern machines. work piece infeed
takes place with a
Highest precision has always been an outstanding strength pal­let system. The
of the Upper Bavarian company Kern Microtechnik. Machi­ com­ plex control of
ning Centers are being developed at Kern in Eschenlohe the manufacturing
and are then being tested in Kern’s own manufacturing cell is done by the
shop in Murnau. Meanwhile, the machining centers are a process control sys-
solid basis for Kern’s machine shop. tem “WorkShopMa­
na­ger”. The robot is Patrick Ginzel, Head of technological
Besides innovative machines plant manager Sebastian an articulated robot management and Sebastian Wühr, plant
Wühr names more decisive factors. “Our staff is very well with an extension manager at Kern Microtechnik, are
trained and very enthusiastic about the perfect solution for length of more than convinced of their robot cell; with the
every challenge. Together with our customers they define three meters (9 feet). robot cell it was possible to gain a
the best possible manufacturing strategy. It is possible for “Since the robot has double-digit increase in productivity
us to already analyze the process even when it is still on to work with four compared to four stand-alone
a prototype status. This way we save a lot of time and it manufac­t uring cen- machining centers
is easy to integrate the process into serial manufacturing.” ters - two Kern Mi-
cros and two Kern Evos - the extension is relevant”, says
A well-known challenge: there are never enough quali- Ginzel and adds “Furthermore, there are two rotary maga-
fied employees. While discussing future strategies the idea zines in use which supply 250 pallet pockets. This is where
came up to increase automation and have one robot work- the pallets - marked with RFID chips - and the clamped
ing with four machines. Patrick Ginzel, head of technologi­ parts are stored, ready to go! “
cal management, became responsible for this project.
He explains: “We decided to look for new ideas and also Machining centers with operating times
integrated external sources to come up with a great solu- of more than 94 %
tion for our automation.” All four machining centers are always prepared for differ-
ent workpieces. This means that a corresponding number
Process control system manages of CNC programs and their manufacturing data are stored
complex production cycles in the WSM, several tool sets are set up and blanks are
The task of the robot cell is to manufacture demanding stored in the rotary magazine for all the workpieces. As a
parts with accuracies in µm- and surfaces in the nanometer result, even a broken tool does not slow down the system.

Kern Microtechnik integrated a robot cell The complex control of the cell is done by the process control system
in their shop; each of the four machining “WorkShopManager”; among others, the system runs an articulated robot
centers has a utilized capacity of 94 % which loads and unloads four machining centers

32 no. 3, September 2020

 machining center

If the worst comes to the worst, the PLS detects the prob-
lem and immediately switches to the second workpiece on
the affected machine.

This becomes important when staff is not around. Of

course, the machines recognize the tool failure also with-
out the WorkShopManager. However, they stop the process
until the failure is being resolved, usually by human be-
ings. Work hours of these four machines are over 90 hours
per workday with this new digitalized strategy. In theory,
96 hours are possible. So, with 90 hours, the machining
center is over 94 % utilized capacity.

Another advantage is, as Sebatian Wühr explains, that

he needs less employees for the reliable operation of this With a touch screen the WorkShopManager makes working
robot cell: “Usually we need one qualified staff member with the robot cell easy; one qualified technician and one or
for the operation of each of our machines. Since it is chal- two assistants are enough to run the robot cell and
lenging at the moment to find more highly qualified team the four machining centers
members, this situation has improved with the robot cell.”
Patrick Ginzel confirms: “It is easy to work with the PLS
and the touch screen. One qualified team member with
the support of one or two team members in training can
easily operate the robot cell.”

How to save precious capacities

of a highly skilled workforce
The qualified technician is responsible for complex tasks
like setting up new products analyzing tool life. In addi-
tion, he eliminates any malfunctions, optimizes the pro-
cess and organizes the cycles. His or her colleagues support
the process with blanks, change the tools when their life-
time - according to PLS - is coming to an end measure the
parts with the help of a quality control chart and bring the
finished parts to the cleaning station.

Four highly precise machining centers - two Kern Micros

Kern Microtechnik GmbH
Kern Microtechnik GmbH, Eschenlohe, Bavaria,
employs 200 people and operates successfully in more
than thirty countries worldwide. The focus is on two
business areas: the development and manufacturing
of high-precision machining centers and the contract
manufacturing of milled parts in the micro and
nano range.
Milling centers from Kern are used in Kern’s contract
manufacturing series production. This enables Kern
to not only manufacture high-precision machines,
but also to support their customers with the necessary
process know-how. Customers become technology
partners and are a part of the “Kern family”. Advice
for ideal operation and process integration are always
included - from an idea to the finished part.
This enables Kern customers to increase their
profit and competitiveness.
The product portfolio of contract manufacturing
includes prototype, single part and series production as
well as mounting assemblies and support in the
construction phase. The parts are machined by milling,
drilling, eroding and grinding.
and two Kern Evos - are integrated in the Kern robot cell;
they produce very demanding parts with accuracies in
the µm- and surfaces in the nanometer range 24/7
What was to be expected by both engineers Patrick Ginzel
and Sebastian Wühr became true. The investment in a
robot cell pays off. The nonproductive times decreased
tremendously and a double-digit increase in productivity
are the result. Ginzel explains: “With these measurements
we even exceeded our goal of 25 %.”
The technology manager thinks ahead and sees addi­
tional potential which he would like to use. Ginzel ex-
plains: “Working with correct tool- and cutting-data is
very important and is one of our core competences. There
is a lot of our know-how in this robot cell. As a result, we
get a lot of feedback about the tools, especially about tool
life and stability.” This information will go back into the
system and this way it is possible to organize the tool
management for every single order even better. Ginzel is
certain: “This will bring another boost of productivity into
the system.”
further information: www.kern-microtechnik.com

no. 3, September 2020 33

 machining center

Tschudin Cube 350 wins Red Dot Design Award

“Unusually elegant”

October last year

the Swiss technology
enterprise Tschudin AG
unveiled the compact and
high-performance centerless
grinding machine Cube 350 at
EMO trade show in Hannover.

The world novelty was a real eye-catcher and trade media

referred to it as “grinding beauty”. Recently, the Cube 350
won the prestigious Red Dot Design Award 2020. The Red
Dot jury explained: “The Cube 350 impresses with a self-
contained, unusually elegant appearance. Thanks to an
innovative layout, the machine is both ergonomic and
efficient at the same time.” With more than 6.500 sub- The design of the Tschudin Cube 350 puts
missions from more than 60 nations in 2020, the Red operators at the center
Dot Award is one of the biggest design competitions [picture source Tschudin AG]
worldwide.

Humans at the center
Tschudin partnered with the Industrial Machines Design
expert Enrique Luis Sardi to develop the Cube 350. “The
design puts humans at the center - it was our goal to cre-
ate a perfect symbiosis between user friendliness, simplic-
ity and elegance,” explains Sardi. The Cube 350 can be
manually loaded both by right-handed and left-handed
people in an ergonomic and secure way - a patent pending
innovation.
But the high precision, triaxial CNC grinding machine
does not only convince with its looks - thanks to innova-
tive automation solutions, the Cube 350 allows the users a
true productivity leap. The Cube 350 features a very small
footprint (2558 x 1735 x 1320 mm), maximum efficiency
and a broad range of process possibilities. Maintenance
and changeover are easy and fast. The Cube 350 was es-
pecially developed for the processing of small components
with a part diameter of up to 20 mm.

Industrial designer Enrique Luis Sardi, Tschudin CEO Iwan “Unusually elegant appearance”:
von Rotz and Tschudin Marketing Manager Emmanuelle Roduit the Tschudin Cube 350 won the Red Dot Design Award 2020
[picture source Tschudin AG] [picture source Tschudin AG]
further information: www.tschudin.swiss

34 no. 3, September 2020


Solid PCD Endmills
A new opportunity for increased productivity
Used in the right application, a diamond (or
PCD - polycrystalline diamond) cutting tool can
last up to 20 times that of an equivalent carbide
tool. The exciting news is, a new generation of solid
PCD helical endmills and drills made on ANCA’s
EDGe machine are set to further extend this advan-
tage. There is strong demand emerging in the 3C
(electronics) and aerospace manufacturing indus-
tries for such tools that can deliver improved pro­-
ductivity and quality in the finished work piece.
As a 5-axis CNC machine, the
ANCA EDGe with its rotary EDGe
process, is ideally suited to create
complex 3D cutting tool forms.
ANCA has a heritage of software
development that supports design
and manufacture of complex geo­
metries on rotary cutting tools
using ToolRoom software. In ad-
dition to helical drill points, our
latest software release allows cus-
Examples of solid PCD tomers to manufacture helical
tipped ball endmill and endmill (square, corner radius
drill made on EDGe and ballnose) forms.
This capability is coming at just the right time for PCD
cutting tool manufacturers, as there is an alignment of
market and technology developments making solid tipped
PCD tools economical and desirable. Users of PCD tools are
asking for longer life and better cutting performance than
is possible with a shear cutting edge on a traditional PCD
tool. The aerospace and 3C industries in particular, are
driv­ing this. Additionally, the solid PCD tip production
process­es have matured and with that, have become more
affordable.
Flexibility sets PCD tipped tools apart
Solid PCD tipped tools offer a number of advantages. Most
importantly, is the complete flexibility in tool geometry.
The EDGe machine’s ToolRoom software allows user to
create helical cutting tools, both drills and endmills, with
far superior cutting properties compared
to equivalent tools with brazed planar
PCD inserts.
A con- Traditional PCD rotary cut­-
ventional ting tools feature flat PCD
brazed PCD tips brazed onto a car-
cutter has shear bide tool body.
cutting edge that While the PCD
limits cutting perfor- will extend the life
mance of the cutting edge, by
machining center
design the cutting geometry is a A solid PCD tip is
shear (straight) edge with a flat brazed onto carbide
hook face. This geometry inher- shaft and then used to
ently limits the performance of create helical tools
the tool.
With solid PCD tipped tools, tool designers can have
greater flexibility to create unique geometries specific to
various cutting applications, in the same way this is done
for conventional carbide tools. This applies not only to the
cutting profile, but importantly to flute and gash geometry
that are critical to chip formation and evacuation.
Another important consideration is
that while the smallest tool diameter
for brazed PCD tools is typically 6 mm,
solid PCD tipped tools can readily be
made much smaller than this. Micro
tools (drills and endmills) are gaining
widespread use in the 3C market with
the EDGe capable of producing drills
down to 0.3 mm and milling cutters
under 3 mm.
Finally, unlike coated carbide tools, The EDGe is
these new drills and endmills can be capable of making
readily resharpened many times, effec- solid PCD tipped
tively extending the tool’s usable life. drills under 1 mm
ANCA’s EDGe machine has all the capabilities you need
to produce these unique tools. Of all the forms of PCD ma-
chining processes, rotary erosion that is used by the EDGe,
is by far best suited to producing solid PCD tipped drills
and endmills. Wire erosion cannot create flute or gash
forms, and laser ablation has highly expensive upfront cost
and is ultimately uneconomical on anything but the very
smallest of solid tools.
ANCA’s EDGe has both electrical discharge machining
and carbide grinding capability. This is an important con-
sideration given these solid PCD tipped tools will naturally
require the flute and OD form to extend into the carbide.
With both electrical discharge machining and grinding ca-
pability, you have the choice to select the optimal process
for different material removal. Built on a heritage of sol-
id carbide grinding capability, ANCA ToolRoom software is
renowned for its inherent flexibility and ease of use.
ANCA EDGe is a highly versatile machine that performs
equally well in other applications such as conventional
brazed PCD shear tools and solid carbide grinding.
further information: www.anca.com
no. 3, September 2020 35
machining center

Contactless processing
The laser as a turning tool takes cutting technology to a new level

Turning is one of the oldest and most impor- nent and the tool size, make machining more difficult and
tant manufacturing processes for the production even make it impossible with particularly sensitive geome-
of components in almost every industrial sector. tries. This is especially true when materials are needed that
Since the Middle Ages, this process is being con- are considered difficult to machine.” Several years ago,
tinuously developed and adapted to the changing GFH GmbH therefore demonstrated the possibility of turn-
needs. The cutting technology, however, brings ing and grinding with lasers on its universal laser micro-
the producers to the limits of the technical trans- machining systems and delivered the first productive solu-
ability, particularly with regard to small and very tions. However, the full potential of the new manufactur-
small components. ing technology could be only partially exploited because
the machines were not designed for these applications.
Tool wear, tool life, machining forces and heat affected There were limitations, for example, in terms of the speed
zone became a limiting factor. But now the laser experts of rotation of the components, the efficient use of laser
from GFH GmbH raise this manufacturing method to a radiation and generally the complete workflow. These
new level: the conventional turning tool is replaced by a limitations have been eliminated with the new machine:
contactless laser that evaporates the material with ultra-­ “After several years of intensive development work together
short laser pulses. This technology has been integrated with reference customers and supported by European re-
from the GFH into a specially designed production ma- search funding as part of the Horizon 2020 project, we can
chine. The process-related technology disadvantage of the proudly present our new turning and grinding solution,”
lower removal volume per unit compared to the cutting reported Lendner. “It is available as a double spindle in
process is eliminated by the double-spindle concept. The short and/or long turning design, optionally with a rotat-
GL.smart equipped with this technology, in conjunction ing swivel unit as a counter spindle. This means there are
with the integrated CAD/CAM solutions, represents the no limits to the complexity of the components, and even
next milestone in the history of turning. end machining is possible.”

“Rotosymmetrical components are in the course of
minia­turization even smaller and more sophisticated,” re-
ports Florian Lendner, CEO of GFH GmbH. “This is where
conventional manufacturing technologies reach their
limits, because the cutting forces, that act on the compo-
All-round talent for rotationally symmetrical
precision components
In addition to pure turning and grinding processes, the
machine is also able to perform drilling, cutting and en-
graving operations - without any remodeling work. This
makes the GL.smart an all-round talent for rotationally
symmetrical precision components. A key factor is the
combination of high process speed with absolute preci-
sion. For this purpose, the air-bearing main spindle is ac-
celerated a torque drive in a position-controlled man-
ner up to 3500 rpm within 0.4 seconds. Radial and axial
concentricity in the nanometer range enables production
with grinding tolerances. A force-controlled tension collet
system with wobble correction and automatic bar feed
represents the interface to the component.

As the newest machine in the GL series, the GL.smart

With up to 16 simultaneous axes, the new GL.smart
represents the all-round talent in the field of laser
micromachining and can fully exploit the flexibility
that the laser offers
with dimensions of 2,212 mm x 1,026 mm x 2,320 mm (l
x w x h) offers productivity in the smallest of space. In ad-
dition to its compact design, the system impresses with an
innovative, black glass housing. This granted in addition
to full protection against laser radiation, a safe shielding
from X-rays that has been proven by test methods. By us-
ing high-power lasers in combination with beam splitting,
simultaneous processing on two stations is possible, which
means double output. “On request, the machine can also
be equipped with a bar feeder as a loading unit. In com-
bination with integrated component handling by means
of robots we offer a fully automated solution for the 24/7

36 no. 3, September 2020


production of parts without restriction,” explains Lendner.
In addition, SPC and N.O.K. parts are kept separate and
can be taken via robot without interruption of production.
Application fields of medical applications
to watch industry
The applications of the new GL.smart are diverse and
range from medical technology for the production of
micro tools such as tweezers, micro blades or implants
to the watch industry for the manufacture of so-called
pivots, which are installed in the clockwork. The advan­
tages of laser processing are, on the one hand, the attrac-
tive production times, which can be achieved thanks
to the roughing and finishing process using ultra-short
pulse lasers. In a first step, as much material as possible is
removed by roughing with a high energy input. For the
finishing, the final quality is achieved in the finishing
process with less energy. On the other hand, almost any
material can be used for non-contact, wear-free machining
of even the smallest components.
Laser turning enables unusually high accuracy, particu-
larly in the manufacture and processing of precision parts,
so that other, more complex processes such as conven­
tional grinding or roller burnishing can be saved, explains
Lendner. “Thanks to the non-contact removal, the work-
piece remains free of force and deformation during the
entire machining time. This means that there is no loss of
accuracy even with very thin and delicate components.”
Because of this also parts with a large length can be easily
machined.
Control software based on more than
twenty years of process experience
The systems can also be freely programed and controlled
using the GL.control software, also developed by GFH,
The use of high-power lasers in combination with beam splitting
enables simultaneous processing on two stations, which means
double output at the same time
machining center
The areas of application of the new GL.smart are diverse
and range from medical technology for the production of
micro tools such as tweezers, micro cutting or implants
to the watchmaking industry for the manufacture of
so-called pivots that are installed in clockworks
based on software process know-how from more than
twenty years. “Thanks to our own software development
and daily use in-house, GL.control is in a constant process
of improvement and further development,” says Lendner.
“The intuitive and simple operating concept, the integra-
tion of the CAD-CAM functions as well as the complete
integration of all subsystems, such as the laser, scanner or
drilling optics make it easier for the user to operate the
machine true to the motto ‘only one software to control
everything’.”
The PLC of GL.smart, is the fastest CNC control on the
market and has been specially designed for laser process-
ing in a development process for more than ten years. This
control offers real-time access for the laser control, so that
the laser can be switched on with an accuracy of 40 nm
at full dynamic of the axes. “Thus the GL.smart not only
convinces with its very compact and innovative design,
it also combines precision, flexibility and productivity in
an attractively priced laser system that leaves nothing to
be desired.
The GL.smart is available as a double spindle in short
and/or long turning design, optionally with a rotary
swivel unit as a counter spindle
further information: www.gfh-gmbh.de
no. 3, September 2020 37
machining center
Next generation of 6-axis tool and cutter grinder
and humanoid power by Rollomatic:
GrindSmart 830XW
The GrindSmart 830XW is the state-of-the
art 6-axis tool and cutter grinder designed for
the production of high performance tools up to
Ø 32 mm. This new model integrates the innova-
tive combination of hydrostatic technology and
linear motors to produce large and small series.
This concept provides an exceptionally high degree of
rigidity and dampens vibrations that naturally occur
during grinding, thereby increasing the life of the grind-
ing wheels and guaranteeing surface finishes and sharp
cutting edges that give users a real competitive advantage.
Equipped standard with a Fanuc robot with a capacity of
10 cassettes (up to 4,500 pieces) and a 15 positions wheel
changer.
GrindSmart 630XW3 and 630XW
The latest generation of GrindSmart 6-axis precision tool
and cutter grinders integrates the latest linear motion
technology, combined with the torque motor on the ro-
tary axis which provides more benefits, such as enhanced
surface finish and reduced maintenance costs. The oil used
for cooling and lubricating the linear motors is the same
as the coolant oil. This ensures consistent thermal stability
during setup and production without incurring additional
energy consumption.
Both machines are designed for both long and short
batches. They include an automatic tool loader of up to
1,360 parts capacity along with either a high-speed wheel
& nozzle changer with 16 positions on the 630XW3 or 6
positions on the 630XW.
38 no. 3, September 2020
The 6th axis concept of this machine is unique in the
grinding industry. It provides improved accuracy on ball-
nose endmills, or corner radii.
For GrindSmart 830XW, 630XW3 and 630XW two inno-
vative measurement processes are available, touch probe
and laser for unattended production, enabling the
GrindSmart to offer an unparalleled productivity rate
that can reach a 99 % uptime.
Geared towards Industry 4.0 solutions, all the machines
come standard with the complete VirtualGrind®Pro soft-
ware offering the designer a variety of choices for the tool
he needs in only a few clicks.
ShapeSmart® NP50
Based on the method of peel grinding, a technology in-
vented by Rollomatic, the ShapeSmart®NP50 is designed
for both long and short batches and covers a range of
diameters between Ø 0.025 and 25.0 mm. This grinding
method is used for blank preparation, core pins and
punches.
To extend the application range of ShapeSmart®NP50,
Rollomatic has developed a new-patented method of peel
grinding (US10207382): SmartPunchTM. This innovative
technique allows the design of an unlimited number of
non-round applications such as ellipses, eccentric shapes,
squares, triangles or hexagons in just a few clicks and
always with the same wheel geometry.

LaserSmart 510
The LaserSmart 510 builds in faster cutting speeds of up to
450 % over Rollomatic’s previous laser machine. The laser
machining process used on the LaserSmart 510 is infinitely
superior to any other traditional method of machining
super-hard materials, such as PCD, CVD diamond, mono-
crystalline diamond, natural diamond and PCBN.
This machine offers the following additional benefits:
♦ unique laser process creates razor-sharp
cutting edges with a radius of less than 1 µm
♦ unique to the market, programmable defined
cutting edge preparations offer total freedom
and flexibility to enhance your cutting tool’s
performance during machining
♦ the machining process is offset-independent and
is unrelated to the amount of offset on the raw
brazed PCD material; there is no increase in
cycle time and no additional blank preparation
is necessary within the machining process
machining center
♦ cylindrical margins are machined all within a
single clamping
♦ 3D machining
♦ sharpening of diamond coated carbide cutting tools;
the use of a full 6-axis robot system provides high
flexibility and compactness to this model, allowing
it to accommodate several performance-enhancing
systems:
• HSK63 station including 17-tool magazine
• round shaft automation with a user-friendly
drawer for tool loading
• extremely simple handling for interchangeable
inserts
Humanoid Power
NEXTAGE®: Next-Generation Industrial Robot
NEXTAGE® is a new type of humanoid industrial robot
that, given its human-like frame, can easily be placed where
a person used to stand and perform tasks in locations that
are difficult for traditional robots. It uses its head and
two arms, equipped with cameras, to take over any te-
dious, dangerous or repetitive tasks, allowing workers to
focus on areas that require creativity and generate greater
added value. Considered as a true “partner” in work, it can
be installed easily and without redesigning the production
line. With a load capacity of 3 kg per arm, this robot is able
to handle a variety of applications. Thanks to a high flex-
ibility of movement, NEXTAGE® can rotate one turn on
itself, respectively distributed between two +/- 180°.
further information: www.rollomatic.ch
no. 3, September 2020 39
components
Smart working for the tool industry
Digitisation is really taking off, especially in
this difficult year. Almost every company is now
forced to face this challenge. But challenges are
opportunities which we should seize, because in
the end they can bring us great added value.
Get Ready for the Digital Age
Smart working is becoming more and more important.
But is the concept also an option for tool manufacturers?
– Definitely! However, we need smart applications which
allow people to work remotely from home or on business
trips. It should be possible to create quotations and techni-
cal documents from anywhere. Sketching the tool manu-
ally at the customer’s site is a thing of the past. Instead of
a CAD workstation, the tool manufacturer needs a quick
and easy-to-use program to create tool drawings as docu­
mentation or for the approval.
Easy Handling
Tool manufacturers should not lose their valuable time in
long introduction phases, but should instead be able to use
the software intuitively. The tool manufacturer documents
the tool already in the first online meeting with the cus-
tomer. Manufacturer and customer can review the tool to-
gether through screen sharing. The customer can thus fol-
low and take part in the drawing, and – if everything fits
well – approve it immediately.
After having completed and approved the drawing, the
tool manufacturer can immediately generate the digital
tool data for the collision check at the customers CAM.
Highest precision under dynamic conditions
Rotary spindle and built-in motor spindle
Used for free-surface machining, the Microlab
rotary head spindle has high torque and high rigi­
dity and is applicable to 5-axis machining centers.
The Microlab built-in motor spindle stands for high speed,
high precision, high efficiency, high quality, and die/mold
machining.
M3-LMSN M4-HMSC
40 no. 3, September 2020
Digital twins
When the customer gives the final release, the tool manu-
facturer can then export immediately the digital tool data
for the production from one and the same master data set.
Smart Working thanks to Digital Tool Data
The software which the ISBE GmbH has developed exact-
ly for this purpose is called ISBE TD Sketcher. This solu-
tion enables tool manufacturers to implement their smart
working concept. Users can create quote drawings easily
and comfortably from anywhere. At the same time, they
generate the digital tool data for the manufacturing. Tool
manufacturers are therefore equipped for future smart
working and are able to deliver their customers from any-
where and at any time.
ISBE GmbH supports its customers in making digital tool
data available at the right time and in optimizing their
own internal business processes. Since more than 20 years
the software developer makes grinding tools smarter.
further information: www.isbe.de
Designed for high speed machining, the built-in motor
spindle produces little noise and vibration. At each produc-
tion stage, the frequency and amplitude response are mea-
sured to guarantee operational stability and quality of as-
sembly and to achieve the highest precision under dynam-
ic conditions. Each manufactured spindle goes through
computer analysis to ensure optimum stability, long opera-
tional life, and low maintenance costs.
M2-QMS M4-RMSC
further information: www.twspindle.com.tw
 components

Reducing the ecological footprint in

tool production
Creating optimal conditions with resource-saving
grinding oil filtration

Climate protection - the challenges for society
and industry are enormous. Resource-conserving
production, sustainability, climate and environ-
mental protection and the task of reconciling all
these demands with economic efficiency while
generating profits is challenging. The potential to
reduce the ecological footprint in many produc-
tion plants is often maxed out not yet fully. One
example is metal processing, especially tool grind-
ing. Those who, in addition to state-of-the-art
grinding technology, also rely on the right cool-
ant filtration can produce more sustainably.
Steffen Strobel, Technical Sales Manager of the mechanical
engineering company and filter manufacturer VOMAT in
Treuen/Germany states: “Political commitment or the set-
ting of goals is not enough. What is needed now is a solid
action plan and the right market-based incentives to
switch to alternative and climate-friendly technologies.
Today many of our customers in the tool industry already
want to grind their tools in the most resource-efficient way
possible. In sales or planning meetings, they are increas-
ingly asking whether our filter systems can contribute to
sustainability in production in addition to being highly
efficient and contributing to quality. Yes, as a manufacturer
of ultra-fine filtration technology, we provide technologi-
cal solutions that give tool manufacturers many impulses
for resource-saving coolant fine filtration”.
Exploiting optimization potentials
In tool grinding, the filtration system provides the grind-
ing process with lubrication and cooling in a pre-defined
purity and volume flow. The heart of this system is the fil-
tration of the cooling lubricant. Optimally filtered cooling
lubricants have many positive influences on the manufac-
turing of cutting tools. In particular, they make the grind-
ing process more economical and contribute to achieving
high quality finished tools. Coolant lubricants, which no
longer need to be changed as often, not only help to re-
duce maintenance time, but also lower the costs of fluid
purchase, storage, recycling and energy consumption.
Steffen Strobel: “To guarantee high levels of production
efficiency with a quality outcome - and to exploit ratio-
nalization and sustainability potentials - VOMAT provides
high-performance filtration systems that combine all these
technical advantages despite their compact design and
small footprint”.

VOMAT’s modular and expandable
KWS 250 chiller is equipped, complete
with circulating pump and Eaton controls;
cooling capacity is 250 kW for brine
operation with a control accuracy
of +/- 1.0 K
During cleaning in the full-flow process,
VOMAT ultra-fine filtration systems
provide permanently clean oil in NAS 7
quality; demand-oriented filtration
and backwashing ensures less load
on the filter components and reduces
energy consumption
VOMAT manufactures
filtration solutions - from
small stand-alone units to
large-scale industrial cen-
tral systems - which sep-
arate 100 % of dirty and
clean oil in full flow by
means of durable high-
performance pre-coat fil-
ters. The purity achieved
is 3 - 5 µm (NAS 7 stan-
dard). State-of-the-art fil-
ter, cooling and disposal
technology - including
HSS pre-filter systems for
mixed processing if re-
quired - ensure economic
and ecological success.
In addition, VOMAT fil-
ters are low-maintenance
and, due to their com-
pact design, take up little
valuable production floor
space.

no. 3, September 2020 41

components
The filter system can continue to operate during the removal
and disposal of recyclable material; the sludge is deposited
directly into transport containers provided by the
recycling company
Adapted filtration performance
to the production process
In VOMAT systems, the filter flow and backwash cycles
are automatically controlled as required. This extends the
service life of the filter elements and saves energy and
costs. According to VOMAT, many conventional systems
on the market permanently filter at full filtration capacity,
even if this is not absolutely necessary. VOMAT systems on
the other hand adapt to the production process. If, for ex-
ample, the grinding machine runs at a slower speed, only
the required amount of coolant is filtered. If a VOMAT
central system provides filtration for several grinding ma-
chines, and some are not in operation, the filter capacity
automatically adapts to the machining volume. At the
same time, less cooling capacity is required. This reduces
the energy consumption even further.
The new VOMAT Vacuum Belt Filter UBF is designed
for filtration of water-based coolants, emulsions and
grinding oils all in a very small space
42 no. 3, September 2020
The machine supply pumps are exactly matched to
the VOMAT filtration system, both in capacity and
performance; the cleaner the grinding oil the longer
it can remain in the system and can provide better
protection for machine pumps and lines
During cleaning in full-flow mode, the demand-oriented
backwash cycle provides further advantages: With VOMAT
filters, the backwash cycles are triggered by the degree of
filter cartridge contamination. Once the relevant values are
reached, the backwashing process begins, during which
each filter is backwashed individually and with a time de-
lay. The other filters ensure a continuous supply of clean
oil. In the disposal unit, the dirty oil is separated from the
sludge and then fed into the dirty oil tank. This fully auto­
matic control of the filtration system keeps energy and
operating costs low.
In addition, VOMAT technology controls the temperature
of the coolant during the grinding process within a range
of ± 0.2 K. The high-precision temperature controls keep
the coolant temperature always constant within the pre-
selected range. This means that the grinding oil in use will
have a long life cycle. VOMAT systems permanently cool
down the coolant during continuous operation. VOMAT
offers various design options for their cooling systems,
such as pallet- mounted units for easy removal and re-as-
sembly on site without service personnel, and auxiliary
units with external condenser for cooling. Ano­ther option
is a cold water-operated cooling system with a closed loop
piping system, such as the VOMAT’s modular and expand-
able KWS 250 chiller is equipped, complete with circu-
lating pump and Eaton controls. The cooling capacity is
250 kW for brine operation with a control accuracy of +/-
1.0 K. The unit does not require a buffer storage tank and
can be installed in industrial outdoor areas. The VOMAT
KWS 250 is very energy-efficient and ensures high-preci-
sion temperature control.
Steffen Strobel: “Thanks to the on demand backwashing
technology and the highly accurate temperature control,
the service life of each individual filter cartridge as well
as all machine components is significantly increased. The
optimal cleaned coolant can remain in the system for ex-
 components

tended periods of time, which saves filtered from cooling lubricants - such production area. Steffen Strobel: “Our
money and energy.” as water-based media - without a pre-­ systems manage the balancing act be-
filtration system to a filter fineness of tween productivity and environmen-
Efficient recycling of 10 to 30 µm.” tally friendly pro­duc­tion. Sustainabi­-
valuable materials: getting lity also means to get the most out
the most out of your coolant According to VOMAT, the compact of the entire production process. The
Not only advanced high-perfor- UBF unit is extremely easy to main- bottom line is that VOMAT techno­
mance filters, which clean coolants tain and, due to a special belt guide logy saves many resources such as ma-
extremely well, ensure energy effi- design, takes up about 70 % less space chines, working time, space, energy
ciency, but an automatic sedimen- than conventional systems. In compar- and raw materials.”
tation system also allows for sus- ison to other systems on the market,
tainable recycling. Thanks to the VOMAT provides three times as much
further information: www.vomat.de
pro­ prietary design features of the filtration capacity per square meter of
VOMAT system, the grinding sludge
has a residual moisture content of
only 5 to 10 % after settling. The
filter system can continue to oper-
ate during the removal and disposal
of recyclable material. The sludge
is deposited directly into transport
con­ tainers provided by the recy-
cling company. Contamination by
filter aids such as cellulose or resi-

UNLEASH
dues of paper bands are eliminated
with the VOMAT technology. This
not only saves money but also re-
sources and the environment.

VOMAT ultra-fine filtration units

can be used for tool grinding ma-
chines processing carbide and HSS-
steel or for a mix of the two. VOMAT
systems are available in various si­zes:
THE CUTTING POWER
standard flow rates are 70 liters/min-
E S T R A M E T S 7 7 – T H E CO O L A N T R E VO L U T I O N
ute, 120 to 420 liters/minute and
480 to 960 liters/minute. In addi-
tion, customer-specific system con­
fig­u­rations can be build up to capa­
ci­ties of an industrial central system.

The systems can be adapted to

customer-specific or increased indi­
vidual requirements by means of
various expansion modules, such as
special cooling concepts, machine
pumps, additional tanks and recy-
cling options.

Multi-talent vacuum
belt filter (UBF)
Steffen Strobel: “Another example
of our market-driven, sustainable
fil­
tration technology is the new
UBF vacuum belt filter for the filtra­
tion of water-based coolants, emul-
sions and grinding oils in the small-
est of spaces.

With the VOMAT UBF, fer-

rous and non-ferrous alloys, HSS,
disc abra­
sion, binders, etc. can be

Oemeta Chemische Werke GmbH estramet.com

components
CNC upgrade program provides US cutting tool
manufacturer with major productivity advantage
US cutting tool manufacturer McQuade
Industries, Inc., has gained a highly cost-effec-
tive productivity advantage by implementing a
CNC upgrade program for a line of 5-axis insert
grinders. The upgraded machines are much easi-
er to set up and operate, which has enabled the
company to shave more than ten minutes per
part off the production time of complex geometry
cutting tools.
Founded in 1978, McQuade Industries has built an envi-
able reputation in the metal cutting industry for the very
high quality of its precision indexable cutting tools. The
machines that are being upgraded are RS12 insert grind-
ers, originally manufactured by Ewag AG in Switzerland.
McQuade installed a number of these highly regarded pre-
cision grinders back in 1988, and over the years they have
provided stalwart performance.
Aside from the fact that the insert grinders still represent
a valuable asset, McQuade had developed a large number
of part programs over the years, which ideally would
need to run on any replacement machines without re-
quiring modification. The company therefore decided to
preserve its investment by implementing a program
to upgrade the machines’ CNC systems, and subsequent-
ly engaged the services of Advanced Machine Technologies,
LLC., a specialist CNC retrofit company based in Owosso,
Michigan.
RS12 insert grinder after upgrade
The original RS12 insert grinders were fitted with NUM
760 CNC systems, NUM Guttinger NGS 610 servo drives
and NUM/SEM brushed servomotors. Having partnered
with NUM on numerous automation upgrade projects over
the past 22 years, Advanced Machine Technologies has
considerable experience in replacing legacy systems such
44 no. 3, September 2020
as these. In this in-
stance, the company
recommended up-
grading to NUM’s
l a t e s t- g e n e r a­t i o n
Flexium+ 68 CNC
system, and replac-
ing the drives and
motors on all five
axes with NUM-
drive X digital ser-
vo drives and new
NUM brushless ser-
vomotors. The all-new Flexium+ CNC system
By transitioning to NUM’s Flexium+ CNC platform,
McQuade would secure full grind cycle flexibility while
continuing to use a familiar HMI (human-machine inter-
face) and machine setup operations. This upgrade path
also provides full backwards compatibility with part pro-
grams that the company had made over the last thirty
years. Furthermore, the embedded PC in Flexium+ repre-
sents a flexible IIoT platform which is Industry 4.0 ready,
offering McQuade powerful connectivity advantages for
future productivity enhancements and enabling NUM or
AMT to provide remote support services if required.
McQuade sanctioned the work, requesting that
Advanced Machine Technologies initially upgraded a sin-
gle machine so that its performance could be evaluated
before progressing further. As part of the upgrade, in ad-
dition to the CNC system, drives and motors, the insert
grinder was fitted with a new NUM FS-12 touch-sensitive
operator’s panel, an MP08 machine panel, and an HBA
series portable hand-wheel. The variable frequency drive
for the existing grinding spindle motor was also replaced,
using a smaller footprint NUM DriveX servo drive to ful-
fill the role. This approach has the advantage that all com-
mand, feedback and status information is now exchanged
over a fast digital bus, which simplifies wiring and im-
proves diagnostic capabilities.
The upgrade has proved a resounding success. The
move to all-digital drives and motors has significantly in-
creased the overall speed and performance of the machine,
resulting in faster grind feed rates and improved surface
finishing.
The first upgraded RS12 insert grinder is now in full
operation on McQuade’s production line, and the company
has already commenced upgrading the next machine on
the line.
further information: www.num.com
 components

Sludge Barrier removes impurities

Retrofittable separation system removes sludge and
residual particles from the cooling lubricant

Mayfran International, the specialist for mate-
rial handling and coolant treatment in the metal-
working industry, has developed a “Sludge Barrier”.
The magnetic separation system for the cooling
lubricant tank, which can also be retrofitted, re-
moves iron particles. It is suitable for all machin-
ing processes involving magnetic materials such
as steel, cast iron or nodular cast iron. It can also
be used in washing systems for parts cleaning.
Light and portable
The Sludge Barrier is available in different sizes and de-
signs: The Manual Sludge Barrier (SB) catches the chips and
small iron particles with a built-in magnet. The stainless
steel construction is particularly compact and easy to carry.
It works in water and oil-water emulsions with tempera-
tures up to 60 ° Celsius. The sludge is emptied manually at
certain intervals by means of a demagnetising lever. This
means that the unit does not need its own power supply.
Retrofitting to practically any existing coolant tank is
possible without any problems. Two sizes, which differ in
terms of magnetic flux density and their maximum ab-
sorption capacity, are initially available. The SB4012 offers
a maximum holding capacity of 1.6 kg of cast iron chips or
approximately one kilogram of short steel chips at a flux
density of 970 Gauss (0.097 Tesla). The SB4024 reaches
1200 Gauss (0.12 Tesla) flux density and can hold up to
3.6 kg of cast iron or 2.7 kg of steel chips.
Automat also removes tramp oil and
floating sludge
The Auto Sludge Barrier (ASB), also made of stainless steel,
catches the particles on a circulating magnetic strip. A
long drying zone ensures that the sludge is as dry as pos-
sible before it is automatically discharged into a collection
container. Its compact design combines high performance
with a small footprint. An easily adjustable timer function
minimizes coolant carry-over. In addition, the ASB also
removes tramp oil and floating sludge from liquids in a
machine tool.
The automatic version of the Sludge Barrier can also be
retrofitted to practically all existing coolant tanks. In the
50 Hz version for Europe, it generates a magnetic force of
900 Gauss (0.09 Tesla). This enables the ASB to extract
up to 40 kg of cast chips per hour (approx. 60 liters chip
volume) or 30 kg of short steel chips (approx. 50 liters chip
volume) per hour from the cooling lubricant. In addition,
the ASB can remove up to a third of a liter of tramp oil
per hour.
Protects the environment and
pays for itself quickly
The sludge barrier combines economy and ecology, as a
typical example shows. In a metal- working company, the
lubricant tanks of the machine tools had to be cleaned
every two months on average. Effort: up to two days.
During this time, machines and workers are not produc-
tive. The Auto Sludge Barrier could be installed almost
without interrupting production and immediately re-
moved kilograms of sludge from the tanks.

The tank cleaning

intervals could then be
extended from two to
almost six months. The
costs for the coolant were
reduced by up to 30 %.
But that’s not all, the
cleaner KSS also in-
creased the service life of
the tools. In less than six
months, the ASB had re-
couped their costs - and
significantly reduced the
burden on the environ-
ment thanks to the lower
Cleans cooling lubricants and lets them live longer: the new “Sludge Barrier” from Mayfran consumption of coolant
is easy to retrofit and removes iron particles such as steel, cast iron or nodular iron and tools.
by magnetic means, it is available in a manual and an automatic version
further information: www.mayfran.com

no. 3, September 2020 45

components

New Zubora lubricant series for machining

They cover a wide range of applications

With the Zubora 57 series, the lubricant

experts from Zeller+Gmelin present modern,
water-miscible cooling lubricants for machining.
The products, which are free of boron and form-
aldehyde separators, cover a wide range of appli-
cations with their individually tailored additive
concept: from normal to tough steel, aluminium
or cast materials. Even the processing of non-fer-
rous metals is possible in many ways.

According to Zeller+Gmelin, the new water-miscible

Zubora cooling lubricants make a convincing contri-
bution to economical and sustainable production for a
wide range of machining tasks. Products from this new
series can be used even for the most demanding machin-
ing oper­ations. For example, Zubora 57 H Plus is also
ideally suited for grinding as a lubricant for medium-
duty machining opera­tions. The Extra and Ultra products
are even more powerful.
Due to a high proportion of polar additives, Zubora 57
H Extra guarantees an outstanding reliability even for dif-
ficult machining tasks. With additional EP/AW additives,
Zubora 57 H Ultra (for hard water) or Zubora 57 S Ultra (for
soft water) ensures maximum process reliability even for
the most difficult machining tasks. In addition, the semi-
synthetic lubricants with a mineral oil content of 30 %
offer excellent corrosion protection.
Long service life guaranteed: with the optimally coordinated
formulation, the water-miscible Zubora cooling lubricants of
the 57 series score with an excellent price-performance ratio
As studies from the development of lubricants at
Zeller+Gmelin show, the products have a good long-term
stability. Various 5 and 10 % emulsions were tested, made
up with water at 40 ° dH. The samples were then subjected
to an aging test. The samples were stored over a period of
four weeks at room temperature or at 40 ° C. Even in the
“endurance test” at 40 ° C, the samples showed no optical
changes after four weeks, which proves a good long-term
stability. This significantly extends the maintenance in-
tervals, which leads to long-term cost savings for the
equipment.

Whether room temperature

or 40 ° Celsius, without
flocculation and cloudiness:
the cooling lubricant
Zubora 57 H Ultra proves
a high long-term stability

further information: www.zeller-gmelin.de

46 no. 3, September 2020

 components

On the verge of a green and clean era in the metal tool industry:

Ionized, cooled air to replace metalworking fluids

Expensive metalworking fluids are no longer

needed to cool and lubricate workpieces and cut-
ting tools in the machine tool industry. Instead,
there is now a proven green and clean method,
EcoCooling, that uses only ionized and cooled air
and has none of the environmental hazards and
costs related to oil-based fluids.

EcoCooling is the result of long-term, interdisciplinary

R&D from the same team that developed the technolo-
gy behind Amazon’s ground-breaking family of front-lit
Kindle devices. Now the group of scientists, engineers
and experienced businesspeople from various disciplines
has developed a dry, clean and environmentally friendly
method to lubricate metal workpieces with ionized and
cooled air without using any emulsions.
“Workshops have wanted to get rid of fluids and many
have tried to find a solution to the problem, but with
poor results”, says Leo Hatjasalo, co-founder and CEO of
EcoCooling. “Now we have the answer to this demand,
since EcoCooling can be used even with the hardest known
metals like chrome, titanium and tungsten carbides.”
Big market
The global market value for metalworking fluids is esti­
mated at approximately 12 bn $ this year. It is growing
steadily, with estimates for the global market value for
machine tools expected to grow from 120 bn $ to 150 bn $
in five years’ time. The growth is driven, for example, by
the accelerating need for components in the aerospace,
automotive and transport sectors.
“EcoCooling is based on the fact that ionized air pene-
trates the cutting zone and forms a dry lubricant that de-
creases cutting friction and generated heat, at the same
time speeding up the oxide layer formation”, Hatjasalo
explains. “The process is patented on all continents, and
at the moment we are validating it to include all types of
machine tools.”
EcoCooling utilizes cooled ionized-air flow in the
working zone to form a dry lubricant, which decreases
cutting friction and generated heat and speeds-up
oxide layer formation
“The unit does not need any service and it has proved
to prolong the lifetime of the cutting tools significantly”,
Hatjasalo says. “The system can also be easily retrofitted to
older machine tools.”
The big leap is still ahead
During the past few years, EcoCooling has been success-
fully trialled in numerous commercial tests in demand-
ing surroundings internationally. Now that the process has
proved to give excellent results, big savings and substan-
tially less environmental impact, the aim is to create a ver-
satile EcoCooling product family that includes all machine
tools in addition to just turning machines.
“We are also planning to integrate the system to suit
different CNC machine tools and to create optimal solu-
tions for all machine tools and workshop environments”,
Hatjasalo says. “However, for that purpose we need more
funding than we can raise on our own. Therefore, the next
step is to find an industrial partner to help us to commer-
cialize EcoCooling globally and to develop the ways the
technology can be used.”

Hatjasalo emphasizes that EcoCooling is not only a way

to cut down the costs of emulsions, but also a way to im-
prove productivity through higher cutting speed, reduced
wear of cutting tools and minimized maintenance costs.

“Since the metal chips are not contaminated by any flu-

ids, they can also be fully recycled without cleaning”, he
says. “Another big advantage is that it eliminates toxic fluid The experienced team behind EcoCooling:
waste and fumes, in addition to minimizing CO2 emis- Juha Hatjasalo, Leo Hatjasalo, Jori Oravasaari and
sions, since no oil is used. “The technology makes it pos- Jarmo Maattanen (from left to right)
sible to build smaller and cheaper metalworking machines,
further information: www.ecocooling.fi
since the EcoCooling unit is very compact in size.”

no. 3, September 2020 47

components
Increasing the efficiency and agility
of machining companies
Further development of digital tool management software
TDM Systems, the digitalization specialist for
the machining industry, has introduced the latest
version of their TDM and TDM Global Line solu­
tions into the market on July 7. The two main
2020 releases of the digital tool management
software offer numerous further developments
but also offer new modules to reduce tooling costs
and increase their efficiency.
“The challenges facing machining companies are enor-
mous: in order to overcome the current crisis, they have
to reduce their costs quickly and substantially,” stresses
Dietmar Bohn, managing director of TDM Systems. For
him, the key to being more cost-effective, quicker and
more agile in manufacturing is digitalization. Accord-
ing to Bohn, machining companies can now take a fur-
ther step towards networking and data usage thanks to the
latest generation of the TDM and TDM Global Line tool
management software.
“With these latest releases, we are underlining our com-
mitment to working as a full-service provider offering
solutions for the company-wide, digitalized management
of tools and equipment which increase the efficiency and
competitiveness of machining companies,” adds Bohn.
One highlight here is, that with the new TDM Global Line
2020 release, users achieve greater transparency regarding
their tooling costs and key figures. This is possible because
48 no. 3, September 2020
each user can now individually configure its TDM Global
Line dashboard. The relevant reports can then either be
displayed in the dashboard, printed out or simply trans-
ferred to Excel. Since real-time data is always evaluated -
for example, the value of the used and new tools or the
number of items and tool assemblies created - the con-
trolling is valid. “Users are therefore able to keep an eye
on the figures that they need, which makes them signifi-
cantly more decisive in how they do business,” states the
managing director.
In addition to numerous improvements and further
developments in the TDM Shopfloor Manager and the Tool
Crib apps, the latest release also provides new modules in
TDM Global Line:
TDM NC-Program Manager Global Line:
Thanks to the transparent management of NC docu-
ments, this powerful tool guarantees a continuous pro-
duction process. Furthermore, the existing application
expertise is retained by the company.
TDM Purchase Request Module Global Line:
This application can be used to easily manage tool
requirements and forward them to the ERP system. This
also makes the tool orders more transparent, which
helps the company to provide all of the required tools at
the right time and in the right quantities.
With the
Global Line 2020
release, users can keep
an eye on all tool data

TDM Barcode Module Global Line:
This module expands the Global Line Tool Crib perfectly
and allows companies to easily control processes by
using barcodes. Users in the area of crib logistics can
therefore work quicker and with fewer errors. Further-
more, this module supports the automation of various
workflows.
TDM 3D Solid Editor Global Line:
This editor can be used to easily modify and adapt 3D
models. Companies therefore achieve significant time-
savings when creating 3D models. The graphics quality
is also increased and the 3D models can be put to even
better use for simulation analyses.
In addition to TDM Global Line, the Tübingen-based tool
data specialists also further developed their core solution,
TDM.
TDM 2020: New module closes the gaps
between planning and production
With the new release, the TDM Feeds & Speeds Manager,
among other things, is available to users. In conjunction
with the Comara Box, the actual applied cutting data is
recorded, compressed and evaluated directly from the
machine. By comparing the planned cutting values that
In the new TDM release, cutting data is recorded, evaluated and saved directly from the machine
components
are defined in the NC program with the actual applied
cutting values in the machine, in future it will be possible
to specify reliable cutting values as early as the planning
phase. This reduces the risk of machine downtimes caused
by incorrect feeds & speeds and reduces the tooling costs
thanks to more targeted tool selection and procurement.
Furthermore, using this module leads to comprehen-
sive time-savings in planning and production. The use of
verified data in the NC programming also improves the
product quality. Yet another advantage of using the TDM
Feeds & Speeds Manager: the expertise from production
is saved centrally; in other words, even if employees leave
the company, the knowledge is retained.
With the latest release, many of the improvements are
also the result of an intensive exchange with the customers
and/or analyses of the TDM applications in the compa-
nies. In doing so, some applications for data and graph-
ics maintenance have been optimized based on practical
experience, meaning that the full utilization potential for
existing data and graphics can be tapped. With the 2020
release, the completeness check of CAM-specific tool data
has also become more transparent. And yet another cus-
tomer demand has been met: the automated calculation
of collision data. This is something that is particularly
advantageous for CATIA and NX users.
further information: www.tdmsystems.com
no. 3, September 2020 49

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The publisher accepts no liability with regard to PuK.......................................................................................................................... page 3
the facts set out in these articles.
Copyright © 2020 Dr. Harnisch Publications
WIN.........................................................................................................inside back cover

50 no. 3, September 2020

WiN woodworking 2021 BE A NER!

WIN woodworking INTERNATIONAL

the only general international magazine for experts in the
entire woodworking industry.

The magazine will be published in a larger format: 229 mm x 305 mm.

h

We report on all aspects of woodworking from board materials,

incl p+

wood treatment to machines, tools and technical know-how, from timber

engineering supplies to the latest developments in technologies and
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markets.
rate: €

Special features will be presented on design, surfaces, laminating

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and furniture.
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Advertising contact: win@harnisch.com

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