WALTER and EWAG machines integral to United Grinding‘s C.O.R.E. strengths at EMO
Walter Ewag are exhibiting a series of their renowned tool and insert grinding and erosion machines, as well as a tool measurement machine, on the EMO stand of parent company United Grinding Group, The Group also reveals that a revolutionary new customer-focused initiative is being launched at the show and that it will “pave the way for a new generation of machine tools that fully embrace the digital age.”
While details of the United Grinding Group’s C.O.R.E. (Customer Oriented REvolution) will be kept under wraps until noon on the opening day of the exhibition (October 4), United Grinding Group CEO Stephan Nell has announces: “We have invested unwaveringly in research and development both before and during the Coronavirus pandemic, to secure the future, not just for us but, above all, for our customers. When we talk about the future, it is inseparably linked to digitisation and with increasing work simplification in production.”
He adds that C.O.R.E is intended to put the focus back on people and in a truly revolutionary way.
The United Grinding Group stand (Hall 3, Stand E31) will display a host of Group company machines, among them the Ewag Laser Line Precision for entry-level machining of diamond cutting materials such as CBN, PKD, MKD and CVD-D on tools up to 200 mm diameter and 250 mm long, as well as indexable inserts from 3 mm internal diameter and up to 50 mm external diameter.
Highlights from Walter comprise:
Helitronic Raptor Diamond – the entry-level two-in-one grinding and erosion machine for tools of 3 mm to 400 mm diameter and in lengths, including end face operations, of up to 270 mm
Helitronic Micro – for grinding tools from 0.1 mm diameter (in production) and 3 mm diameter (re-sharpening) and up to 12.7 mm diameter, and now up to 220 mm long
Helitronic Vision 400L – for grinding tools of 3 mm to 315 mm diameter and up to 420 mm long
Helicheck Plus tool measurement machine – for inspecting tools up to 330 mm long and 1 mm to 150 mm diameter
parts2clean 5 to 7 October in Stuttgart
Companies from the parts and surface cleaning sector are looking forward to the first physical highlight of the year: from 5 to 7 October, Deutsche Messe stages parts2clean in Stuttgart. With their wide range of products, solutions and services, numerous market leaders from Germany and abroad present their range of application-oriented and cost-efficient cleanliness.
After a Corona-forced pause last year, parts2clean, the leading trade fair for industrial parts and surface cleaning, will return this year to the Stuttgart Exhibition Centre. “Together with our exhibitors, we have decided to stage parts2clean as a physical event again. All companies have a great need to explain their products and solutions to customers in person,” says Olaf Daebler, global director parts2clean at Deutsche Messe. “We also offer companies and visitors who cannot be in Stuttgart an expanded digital offer, but parts2clean clearly emphasises on-site interaction and networking.”
parts2clean focuses on: cleaning systems and alternative cleaning processes; systems and components for cleaning facilities; quality control and assurance; cleaning media; services such as contract cleaning, cleanliness analysis and training; corrosion protection; preservation; packaging and logistics; handling systems and automation solutions; cleaning baskets and workpiece carriers; clean room and clean room systems; research and development; digitalisation.
Each day of parts2clean, Deutsche Messe and the Fraunhofer Cleaning Technology Alliance organise a forum where experts discuss all topics related to industrial parts and surface cleaning, including: the basics and innovations of industrial cleaning processes; challenges from filmic contamination; cleaning for medical and pharmaceutical technology; analytic and technical cleanliness; automation and digitalisation. Electromobility is a new theme in 2021. Admission to the forum is free for parts2clean visitors.
Tel: 0049 511 8931024
2021 ANCA Tool of the Year winners to be announced live at EMO Milano
ANCA Tool of the Year 2021 offers thousands in prize money and global recognition, celebrating the magic of the cutting tool and the experts who create them
ANCA’s industry-first competition is back with the 2021 winners to be announced live at EMO, Milano: a major global trade fair that recognises the magic world of metalworking. Last year the industry welcomed the opportunity to show off their skills with almost 30 entries received from across the world being seen by over 80,000 fans generating over 200,000 engagement on social media. A video announcing the competition ic available at: https://www.youtube.com/watch?v=JBL8CagvGu4.
Pat Boland, co-founder of ANCA comments: “Our industry thrives thanks to grinders’ expertise. Much of what people use and enjoy in everyday life is due to the hard work and ever increasing technical acumen of these cutting tool makers and as a result we are seeing the complexity of cutting tools increase, improving productivity, tool life and functionality.
“Now in its fourth year, ANCA Tool of the Year has gained significant coverage, raising the profile of cutting tools and those companies who make them. I encourage all cutting tool makers to enter our competition and be recognised on a global stage for your craftmanship and contributions to our industry.“
Ivan Cuscov, plant director at Cerin SpA and first time judge says: “Continuous developments in tool technology have shown us that standard products have become easier and easier to make and the challenge is to create something new, putting creativity into the grinding process. Grinding technology can still be surprising for expert people who work in field every day given turning new ideas into reality is enhanced by an open, flexible software such as ANCA’s iGrind.” Cerin SpA began operating in 1971 and is one of the most reputable Italian manufacturer of carbide precision tools.
ANCA will also showcase the much anticipated AutoMarkX for the first time at EMO. AutoMarkX is an automatic stand-alone laser marking station replacing manual and labour-intensive processes. For more information about what is at ANCA’s stand, visit the EMO page on the website.
Complexity through simplicity: ANCA makes it simple to design and grind complex tools
To find the Tool of the Year customers can submit their favourite tool with the winners being judged and announced live at EMO. There will be two competition categories to recognise both the functionality and creativity of cutting tool manufacturers:
The main prize goes to #MadeonANCA tools and entrants will be judged on the form and performance of their cutting tool.
The second category is for virtual tools as the “Most innovative tool design – 2021”. Entrants are encouraged to be creative and use ANCA tool design software to push ideas to their limits.
The winner of #MadeonANCA will receive $10,000 AUD worth of ANCA innovations for parts, accessories or software that fit your grinding needs and the winner of the most innovative virtual tool will receive the full CIM software package.
2020’s #MadeonANCA competition winner, ARCH Cutting Tools’ entry demonstrated excellent use of multiple iGrind operations with several complex profiles. Jeff Cederstrom, president of ARCH Cutting Tools says: “It is a humbling experience to be involved in a friendly competition with some of the world’s most innovative and technically advanced cutting tool manufacturers. We will use the recognition to further motivate us to push the limits of cutting tool design to meet our ultimate goal of meeting our customers’ needs and the challenges they have in their applications every day.”
Pat Boland continues: “In the Virtual Tool category, joint winner JG Group from Poland took a creative approach using an Australian theme of the Sydney Opera House reproduced in a profile tool, looking as impressive as a tool as it does in real life. Turcar’s tool amazed me in how they achieved their tool design. I had no idea our software could produce something as beautiful and as well executed as their entry.”
The competition will be based on the passion and the craft of tool making and celebrate our highly skilled tool grinding community.
The judging panel will comprise: Pat Boland, co-founder and managing director of ANCA; Ivan Cuscov, plant director at Cerin SpA, Italy; Thomson Mathew, product manager at ANCA – Zoller measure profile and diameter
At EMO, the top five finalist tools will be judged on the following criteria:
Best surface finish in Ra (roughness average) value on the flute or gash surface
The tool the that is closest to the nominal tolerance as stated on the drawing in terms of diameter and profile (i.e. if the tolerance on diameter is +/- 0.010 mm and the tool is measured to 0.005, this will rank favourably)
The tool that has been ground to the tightest tolerance as per the drawing (i.e. the tool with the lowest tolerance will rank favourably)
The evel of complexity (i.e. in terms of the number of steps, profiles will rank favourably)
ANCA is a market leading manufacturer of CNC grinding machines. It was founded in 1974 in Melbourne, Australia, where the company still has its global headquarters. ANCA has offices in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA, as well as a comprehensive network of representatives and agents worldwide. ANCA CNC grinders are used for manufacturing precision cutting tools and components across a diverse range of competitive industries including cutting tool manufacture, automotive, aerospace, electronics and medical.
Strengthening of the management
The old and new management of KAPP NILES, from l to r: Helmut Nüssle, Martin Kapp, Michael Kapp, Michael Bär, Matthias Kapp
Young generation bears responsibility
After many years of success at machine tool manufacturer KAPP NILES, Martin Kapp is retiring from the joint management of the company along with Helmut Nüssle. His sons Michael and Matthias Kapp are continuing the family tradition as of 1st July and strengthening the new management together with Michael Bär.
The motivation for strengthening the management, combined with a reorganisation of the areas of responsibility, was not only the retirement of Martin Kapp but also the increasing importance of global markets. “We have decided to broaden and strengthen the management team. This will allow us to focus more on operational topics and intensify our global orientation, especially towards China,” says Martin Kapp.
In the future, Helmut Nüssle will be responsible for China, the most important single market in the group, the coordination and development of the international offices and strategic issues. Michael Kapp will cover the value-creating areas as well as the development and sales, with Michael Bär heading up the commercial part. Martin Kapp will join the advisory board at this time and take over as chairman.
After studying mechanical engineering, the two brothers Michael and Matthias Kapp first worked for other companies and have now been with KAPP NILES for several years. Michael Kapp was previously responsible for production, Matthias Kapp was previously in charge of marketing. The grandsons of company founder Bernhard Kapp would like to maintain and expand the current business areas and increasingly focus on new business areas such as digitalisation and E-Mobility.
Michael Bär brings his years of experience in the commercial sector to the management team. The graduate in business administration has been with the group since January 2012, most recently as division manager for controlling, finance and human resources.
Even with the new management, KAPP NILES remains true to itself: the family-run company has always maintained open communication with its employees and attaches highest importance to stability, independence, and security for the future.
KAPP NILES is a globally operating group of companies with high-quality and economical solutions for finishing gears and profiles and is partner for companies from numerous industrial sectors in the segments mobility, automation and energy. The perfect interaction between machines, tools, and technologies enables extremely precise machining to a thousandth of a millimetre.
KAPP GmbH & Co. KG
Tel: 0049 9561 8661250
KLINGELNBERG to present innovative solutions at EMO Milan
Considered one of the world’s leading trade shows for machine tools, EMO is held in Italy and Germany in alternating years. Headlined “the magic world of metalworking,” the industry meetup will take place from 4 to 9 October 2021, on the fieramilano Rho how grounds in Milan. System-supplier KLINGELNBERG will present its innovations in Hall 02 Stand D14. These include the debut of the Höfler Cylindrical Gear Roll Testing Machine R 300 for high-precision testing technology.
R 300 – the gear noise finder
The Höfler Cylindrical Gear Roll Testing Machine R 300 is the latest machine development in the area of cylindrical gear technology. Due to the increasing quality requirements in large-scale transmission manufacturing, some transmission and vehicle manufacturers now require a certificate of quality for all gears installed in the powertrain. A further driver of ever-higher inspection levels is E-Mobility, which places much higher demands on the noise behavior of a transmission due to the elimination of the combustion engine.
To meet this challenge, KLINGELNBERG is building on roll testing technology, a familiar method from the bevel gear industry that is now moving into the world of cylindrical gears. Designed for all five roll testing methods, this compact machine is the ideal solution for anyone who wants to combine inspection cycles and reduce disassembly costs while benefiting from a user-friendly design. The many quality control requirements for gears can only be met with a flexible test machine.
Depending on the configuration, the R 300 provides the option of using all five roll testing methods. These include the single flank test, structure-borne noise and angular acceleration test, double-flank and helix roll test. Thus the R 300 can be used at every point in the production process chain for cylindrical gears, from monitoring the soft cutting to checking the hardening distortions to evaluating the noise behavior of the installation-ready gear. In terms of axis traversing paths, the R 300 covers the same component spectrum as the tried-and-tested Höfler Speed Viper Generating Gear Grinding Machine. Wheel components can be tested up to an outside diameter of 300 mm. In conjunction with the optional counter support, shafts up to 800 mm long in extreme cases can be analysed to determine their running performance and noise behavior. Yet the machine’s footprint is a compact 2 m2 – saving costs on expensive production floorspace.
Reducing measurement times in serial measurement with a hybrid solution
Klingelnberg first presented the initial development stage of the hybrid solution with optical measuring technology at the EMO Hannover exhibition back in 2017. The application at that time centred on digitisation of axially symmetrical gear components. Components such as bevel gears and cylindrical gears, and other geometries as well, can thus be measured with an extremely high point density (digitised), followed by additional processing. This additional processing is extremely flexible. In addition to simply depicting the results as a 3D model, comparisons can be made against a CAD target geometry, or a geometrical evaluation can be conducted by creating sectional views. This application is used for reverse engineering, for example.
Klingelnberg has made significant advances in the Optical Metrology system since 2017. Particularly in terms of sensor systems, measured data acquisition, and further processing, there has been significant progress. For this reason, Klingelnberg has been focusing its efforts on the entire signal chain in optical measuring technology and has joined forces with other development partners to develop a measurement system tailored specifically to the requirements of gear measurement. In this system, the active, current-carrying elements, such as a high-power light source, electronics and signal processing, are arranged separately from the sensor in the control cabinet. The distinct advantage of this is that it prevents thermal effects from occurring on the sensor itself as well as around the sensor, on the 3D tracer head, for example.
With the new measurement system, KLINGELNBERG presents a solution whose sensor system is ideally suited for measurements in the sub-micrometer range. This will allow the tactile pitch measurement to be replaced by optical measurement, significantly reducing measurement times in serial measurement applications.
Founded in 1863, machine manufacturer KLINGELNBERG is one of the leading companies in the gear industry. Thanks to numerous innovations in the areas of calculation, production, and measuring technology, it considers itself a technological leader in this industry. With its acquisition of Höfler Maschinenbau GmbH’s core business in 2012, KLINGELNBERG has added machines for machining cylindrical gears to its range of products, reinforcing its position as a holistic system provider.
Headquartered in Zurich, the machine manufacturing firm currently develops and manufactures at its sites in Zurich, Hückeswagen and Ettlingen. The company also maintains a presence with sales and service offices and numerous commercial representatives around the world. KLINGELBERG solutions are used in the automotive, commercial vehicle, and aviation industries, as well as in shipbuilding, the wind power industry and the general transmission manufacturing industry. Applications range from vehicle drives, aircraft turbine engines, and cement mill gear units to drive systems for ships and oil rigs.
With over 200 patent grants, the company continuously demonstrates its capacity for innovation. Above and beyond this, its 14001 certification and participation in the VDMA’s Blue Competence initiative give credence to the company’s sustainable, environmentally sound business practices.
Tel: 0049 2192 81 370
GSF SEPTEMBER 2021
Sunnen promotes Chris Miltenberger to CEO
Sunnen Products Company has announced the promotion of F. Christopher Miltenberger to the additional role of CEO. He joined Sunnen as President/COO in 2015, with extensive operations, engineering, and business development experience. During his tenure, he has been instrumental in Sunnen’s transformation of global operations, as well as improving customer contact management and relationship development.
Prior to joining Sunnen, he held positions with PlayPower, Inc., NN, Inc., Aftermarket Technology Corporation, and Delphi. He holds Bachelor of Science degrees from Ball State University in Operations Management and Purdue University in Mechanical Engineering Technology, as well as an MBA from Michigan State University.
Commenting on Chris Miltenberger’s promotion, Matthew Sunnen Kreider, who has been Sunnen’s Chairman since 2004, states: “Chris has demonstrated over his six years with Sunnen that he is very capable of leading this organisation. During the last 18 months of Covid challenges, Chris has become the face of Sunnen to our customers, business partners and employees, leading us through these turbulent times.”
Chris Miltenberger notes: “I am truly honored by the faith and trust put in me by the Sunnen family and our board. I am committed to building on Sunnen’s leadership in bore creation and finishing, as well as expanding Sunnen’s footprint as a world class manufacturing partner with our customers. I am fortunate to be leading an already strong team both in St. Louis and around the globe.”
Long the industry leader in honing technology, Sunnen has grown to be one of the largest integrated manufacturers of precision bore creation and finishing equipment. Sunnen’s customers, and their applications, span a range of industries. The product line includes honing, lapping, skiving/roller burnishing and deep hole drilling systems, and a full range of tools, abrasives, and accessories. Sunnen employs 650 people worldwide, with offices, manufacturing and technical support facilities in Europe, China, India, Brazil, Mexico and the US. The company’s expansive international distributor network provides full global support for its multinational customer base.
Sunnen Products Company
Tel: 001 314 781 2100
The Company Rettificatrici Ghiringhelli celebrates 100 years of its foundation and presents the new A80 line.
Detail of the logo which celebrates the centenary of foundation of the company.
by Claudio Tacchella
The company Rettificatrici Ghiringhelli S.p.A., an Italian family-run company headquartered in Luino (VA) and world leader in the manufacturing of centerless grinding machines at very high level of accuracy and quality, is pleased to announce to the whole specialized press and to the prestigious technical trade publications the celebration of the centenary of the foundation of the company. Just to honour such important anniversary, it will present its world premiere at the next international EMO exhibition in Milan (4-9 October), i.e., a new line of centerless grinding machines called A80 (Anniversary). The new A80 will be manufactured by expanding the range of the Ghiringhelli’s products, and by entering the first place for increasing sizes and with technical features suitable for grinding operations with fixed centre on very small technical issues by size.
GSF JUNE 2021
Innovative Grinding Technologies – Fritz Studer Award 2020
Fritz Studer AG has awarded its research prize, the “Fritz Studer Award“ for the sixth time. Applicants from several European countries submitted their work, with the winner of the CHF 10,000 prize announced as Dr-Ing. Mirko Theuer.
The Fritz Studer Award is aimed at graduates of European universities and technical colleges. The targets are creative ideas and solutions in the area of the machine tool industry. “The goal behind the research award is, on the one hand, feasible solutions and ideas which strengthen the innovative power of the machine tool industry and, on the other, our desire to use this award to promote young scientists and technicians,” states Dr-Ing. Frank Fiebelkorn, Head of Research and Technology Fritz Studer AG.
The work sent in for this Award should specifically focus on the following topics:
Innovative machine concepts or components for machine tools for precision machining
Alternative materials in mechanical engineering
Simulation models for the dynamic and thermal behavior of machine tools
Control and sensor concepts for machine tools
New or advanced manufacturing techniques, especially in hard fine machining, such as grinding, hard turning, etc.
STUDER received several studies, master theses and dissertations, with an expert jury evaluating the work. The jury consists of Prof. Dr. Konrad Wegener, Institute for Machine Tools and Production at the ETH Zurich, Dr.-Ing. Hans-Werner Hoffmeister, head of Production Engineering at the Institute of Machine Tools and Production Technology of the TU Braunschweig and Dr.-Ing. Frank Fiebelkorn, head of Research and Technology at Fritz Studer AG. Criteria for the evaluation of the works were for example the feasibility to imple-ment the idea in the machine tool industry, the innovation and quality of the idea, the scientific content and form, as well as the correctness of the statements and results.
This time, the Studer Award 2020 went to Dr. Mirko Theuer from the Institute for Production Engineering and Machine Tools at Leibniz University Hannover. He convinced the entire jury with his study entitled “Continuous generating grinding of cutting tools.“ His work deals with the development of a new type of tool grinding method for the manufacture of cutting tools such as drills, mills or saw blades, for example.
Award winner Mirko Theuer has transferred theoretical and practical knowledge in the continuous generating grinding of gearwheels to the conditions of a 5-axis tool grinding machine, which is normally used for machining such cutting tools. To do this he developed a mathematical model, which serves to design the worm geometry (grinding wheel) for the required cutting tool geometries. The practical tests for continuous generating grinding showed that a wide variety of tool ge-ometries can be designed. The newly developed generating grinding process enables the flutes and peripheral cutting edges of a cutting tool to be produced simultaneously with a sin-gle grinding worm, so that it is no longer necessary to use several grinding tools in succession. The new method increases the productivity of the overall process, as well as the manufactur-ing quality. The improved manufacturing quality also shows benefits for the subsequent use of a milling tool. In comparison to conventional reference mills, a 15% higher service life was established. Dr Theuer presented many other advantages of the new method in detail in his dissertation. The very high degree of innovation of this topic is also underscored by a patent application for the developed method.
“It is a fantastic feeling to receive the Fritz Studer Award. I have always hoped that my dissertation could make an innovative contribution to production technology. This award is therefore a special honour for me,“ enthused Dr.-Ing. Mirko Theuer on receiving the Fritz Studer Award and the prize money in the amount of CHF 10,000.