motion_2011-1_en

A giant leap forward The LASER LINE from EWAG sets new standardsin laser machining

MOTIONTHE CUSTOMER MAGAZINE OF THE SCHLEIFRING GROUP

TOP TRADE FAIR: The SCHLEIFRING Group at the EMO

SPEED AND PRECISION: The new S41 from STUDER

COUNTRY SPECIAL: Focus on Germany

I S S U E 1 / 2 0 1 1

L_S.1_Titel_E.indd 1 21.04.11 18:04

www.winterthurtechnology.com

PROFILE GRINDING WITH WINTERTHUR: PASSIONATELY PRECISE

SwitzerlandWinterthur Schleiftechnik AGOberer Deutweg 4 8411 WinterthurTel.: +41 (0)52 234 41 41Fax: +41 (0)52 232 51 [email protected]

GermanyWENDT GmbHFritz-Wendt-Strasse 140670 MeerbuschTel.: +49 (0)2159 671-0Fax: +49 (0)2159 806 [email protected]

USAWinterthur Wendt USA Inc.10 Viking RoadWebster MA 01570Tel.: +1 (508) 949 10 61Fax: +1 (508) 949 20 [email protected]

AustriaRappold Winterthur Technologie GmbHSt. Magdalenerstrasse 859500 VillachTel.: +43 (0)42 42 41 811 0Fax: +43 (0)42 42 41 811 [email protected]

United KingdomWinterthur Technology UK Ltd.2 Oakham Drive Parkwood Industrial EstateSheffield S3 9QXTel.: +44 (0)114 275 42 11Fax: +44 (0)114 275 41 [email protected]

SwedenSlipNaxos ABFolksparksv. 3159383 VästervikTel.: +46 (0)490 843 00Fax: +46 (0)490 146 [email protected]

GermanyWinterthur Technology GmbHHundsschleestrasse 1072766 ReutlingenTel.: +49 (0)7121 93 24 0Fax: +49 (0)7121 93 24 [email protected]

L_S.2-3_Editorial_E.indd 2 20.04.11 11:36

E D I T O R I A L

3MOTION 01/11

KÖRBER SCHLEIFRING – A Strong Group

Dear Readers,

Yours sincerely,

Stephan Nell

Member of the Körber Schleifring GmbH

Management Board

We have been using our time wisely and, despite the economic crisis,

have continued to press ahead with our research and development

projects, enabling you to make best use of the current upturn in the

economy and ensuring that you will be able to continue working ef-

fi ciently with state-of-the-art grinding machines in the future as well.

For KÖRBER SCHLEIFRING, 2011 is a year of innovations. One of our

new products is the LASER LINE from EWAG, which represents a

quantum leap in laser machining technology and will help you attain

new heights of productivity and quality. The new S41 from STUDER

is another outstanding innovation. It is even faster and more precise

than the previous model and will set new standards of Swiss precision.

You will be able to see these machines and others in action at EMO

2011 in Hanover in September. Of course, our sales staff are also hap-

py to arrange a meeting with you at any time.

KÖRBER SCHLEIFRING combines the strongest brands in the fi eld of

grinding technology with the knowledge of more than 2,000 grinding

experts. This means we are always in a position to offer the right solu-

tion, even for diffi cult jobs.

We are pursuing long-term goals that focus on our customers. The

merger of SCHAUDT and MIKROSA brings together the know-how of

both brands and knowledge about our customers’ requirements.

As well as technical competence, we set great store by personal

customer contact. That is why we are available all over the world – in

Germany and Switzerland, in the USA, where our experts at UGT

are at your service, and in China. There Our Chinese company,

Körber Schleifring Machinery Shanghai, provides services through a

close-knit sales and service network, as well as producing machines

for the local market. With over 300 contact partners, we are at home

all over the world.

I hope you enjoy reading this issue of MOTION.

L_S.2-3_Editorial_E.indd 3 20.04.11 11:36

4 MOTION 01/11

CONTENTS

L_S.4-5_Inhalt_E.indd 4 27.04.11 11:48

5MOTION 01/11

20

Latest news

N E W S

TO O L S & T EC H N O LO GY

Portrait

Frank Ohmenzetter from Leipzig

has worked for MIKROSA for about

four decades

Ice yachting

Perfect blades thanks to BLOHM

Close to the customer

The SCHLEIFRING service advisers

prevent machine wear

On target like William Tell

STUDER employee Hans Flühmann is

an accomplished archer

Major event in Thun

The STUDER MOTION MEETING 2011

M OT I O N S & M O R E

C O N T E N T S

Country special Germany

A nation of poets and inventors

situated in the heart of Europe

From one source

SCHAUDT MIKROSA scores with

good order intake and successful

merger of sites

Particularly high-strength

BLOHM grinds thread rolling

dies for special screws

Grinding instead of milling

MÄGERLE offers solutions for

steam turbines

Aerospace technology from Japan

Mitsubishi Heavy Industries

grinds on WALTER machines

EMO 2011

The latest SCHLEIFRING trends at the

industry’s leading trade fair in Hanover

The new one from STUDER

Cost-effective and quick – the S41

Resolute intervention

Combating cardiac arrhythmia

with JUNG technology

Market of the future: China

The SCHLEIFRING Group is

present in the Middle Kingdom

with its company Körber Schleifring

Machinery Shanghai

M A R K E T S & T R E N DS

06

08

12

14

16

43

22

18

30

34

40

42

20

26

32

36

38

COV E R S TO RY

Laser machining

The LASER LINE from EWAG revolution-

izes work with super-hard materials

IMPRINT

Publisher: Körber Schleifring GmbH, Hamburg Chief editor: Peter Lütjens Realization: JDB MEDIA GmbH, Schanzenstraße 70, 20357 Hamburg, Deutschland, www.jdb.de

Project management: Jan Hawerkamp Art direction: Claudia Schiersch Editorial board: Oliver Haastert (dir.), Julia Böhne, Lutz Günther, Timo Prüfi g, Hauke Schättiger, Ira Schroers, Sarah Sey-

fried Layout: Steffi Pfl ugbeil (dir.) Graphic editors: Julia Poppe (dir.), Nina Weinhardt Proofreading, editing and translation: SKH SprachKontor Hamburg GmbH Photos: action press (1), alimdi.

net (1), Anzenberger (1), bildstelle (1), ddp images (1), fotolia (1), Getty (4), imago (1), iStockphoto (10) mauritius images (2), ullstein bild (1), veer (1), Wolfgang Deuter (1), PR (1) Lithography: Fire

Dept. GmbH, Hamburg Printing: NEEF + STUMME premium printing GmbH & Co. KG, Wittingen

News to use

Practical production tips

L_S.4-5_Inhalt_E.indd 5 27.04.11 11:48

6 MOTION 01/11

N E W S

WALTER

750th service contract

BLOHM JUNG

Committed to GöppingenKÖRBER SCHLEIFRING

New Appointment

team in particular, have strengthened

our confi dence in the brand.’ For this

reason, EMMEBI has signed another

service contract with WALTER at the end

of 2010. It was the 750th in Europe for

the south German grinding experts – and

therefore a reason to celebrate. By sign-

ing the service contract, Sandro Bonet-

ti wants to ensure the long-term quality

of the equipment. His WALTER machines

have to keep running smoothly, espe-

cially during the unmanned night shifts.

For the moment, the entrepreneur can

boast an excellent order book and is

planning further investment for 2011.

EMMEBI currently employs 15 people.

Around 80 per cent of the company’s

production is destined for the Italian

market. The main customer base in-

cludes the hydraulic and pneumatic sec-

tors, the printing industry, die manufac-

turers and mold and tool making.

The manufacture of special tools and step drills – this is what EMMEBI special-

izes in. Based in the town of Pian Camuno in the province of Brescia, the

company operates a total of four WALTER machines. ‘We decided to buy our fi rst

WALTER because the brand has an excellent reputation in Italy,’ says owner Sandro

Bonetti. ‘Based on our positive experience, we subsequently purchased further

machines. The excellent after-sales-service and cooperation with the Italian WALTER

The state of Baden-Württemberg is known for its mechanical engineer-

ing companies. Particularly the manufacture of machine tools in this

state in the southwest of Germany, has recorded an increase in orders of

79 per cent from September to November 2010, according to the German

Engineering Association (VDMA). BLOHM JUNG customers can still fi nd

reliable local contacts in this booming region. The company is currently

setting up a modern demonstration center in Göppingen. Part of this project

will be a new showroom and demonstration area. Sales and service per-

sonnel are available as usual.

BLOHM JUNG Sales Director

Matthias Guhlke explains the

commitment to the location 40

kilometers east of Stuttgart:

‘The complete BLOHM JUNG

range of services is retained

in Göppingen. Our customers

from the south of Germany,

Austria and Switzerland will

continue to fi nd competent

contacts in their area.’

Stephan Nell, Chairman of the Man-

agement Board of Fritz Studer AG,

joined the Management Board of Körber

Schleifring GmbH on February 1, 2011.

He will be responsible for sales,

marke ting and service. He is succeeded

as Chairman of the STUDER Manage-

ment Board by Michael Horn, who has

been a member of the Board since 2007.

Since February, Peter Weber, Managing

Director of Schaudt Mikrosa GmbH, has

also been responsible for sales and

service at STUDER.

een responsible for sales and

e at STUDER.

Closing the contract: (from left) Andreas Ahlers (Walter Maschinenbau GmbH), Sandro Bonetti (EMMEBI),

Mauro Viola and Francesco Vassalli (both from Walter Machines Italia)

The BLOHM JUNG site at

Göppingen: Home of the new

demonstration center

Career move: Stephan Nell

was appointed to the

SCHLEIFRING

Management

Board

L_S.6-7_News_E.indd 6 20.04.11 11:43

7MOTION 01/11

M Ä R K T E & T R E N DS

www.zyklomat.de

Money-back-guarantee for grinding sludge

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L_S.6-7_News_E.indd 7 20.04.11 11:43

Super-hard tools made from PCD,

CVD and CBN become more im-

portant when processing aluminum,

composite materials and other new

materials. The industry is increasingly

calling for these tools to have a longer

service life, a result that conventional

abrasive manufacturing processes can

only partly achieve. Even the creation of 3D contours such as chip breakers is

subject to economic limitations. They cannot normally be manufactured by grind-

ing alone and the eroding process is very slow and expensive.

It is now possible, however, to manufacture extremely hard tools with previ-

ously unattainable properties on the new LASER LINE from EWAG. This is a

Top level performance:

The EWAG LASER LINE

clears every hurdle

L ASER PROCESSING

A great leap forward

The EWAG LASER LINE sets new standards in laser processing of super-hard materials. State-of-the art laser technology enables effi cient processing of external contours and chip breakers in a single clamping.

C OV E R S T O RY

8 MOTION 01/11

L_S.8-11_Titelstory_E.indd 8 20.04.11 11:45

Process benefi t of ‘cold ablation’: Laser pulses in the picosecond range are character-

ized by an extremely short application time. In combination with the great energy

density, the material to be removed is entirely vaporized – without heat being applied

to the workpiece. This substantially improves the surface quality compared with

conventional nanosecond lasers (ns lasers).

ULTRASHORT PULSED LASER TECHNOLOGY

En

erg

y d

en

sity

[W

/cm

2 ]

3 GW/cm2

Application time [s]

Heating

Melting

Vaporization

200 μJ

~ 10 ps

1014

1012

1010

108

106

104

102

10-14 10-12 10-10 10-8 10-6 10-4 10-2 100

9MOTION 01/11

quantum leap in terms of surface qual-

ity, coupled with an unprecedented tool

life. The laser technology used in the

LASER LINE meets the highest require-

ments, as the laser is capable of separat-

ing individual diamond grains, thus

avoiding diamond fracturing. In addi-

tion, the EWAG process also creates 3D

contours on the workpiece – with the

same machine in a single clamping.

Complete machining of super-hard ma-

terials on the EWAG LASER LINE

reduces changeover times, improves

the manufacturing quality of the tools

and opens up entirely new perspectives.

Technology of the future

Laser technology is one of the most

sought-after technologies of the future.

Lasers bundle light into a very small

area and create very high energy densi-

ties. They have now become an indis-

pensable part of metalworking. ‘Lasers

have revolutionized many manufactur-

ing processes. Powerful fi ber lasers and

short pulse lasers offer almost unlim-

ited geometrical design possibilities,

particularly when machining tools

made from super-hard materials,’ ex-

plains Christoph Plüss, Head of Re-

search and Development for EWAG.

Utilizing laser energy for manufacturing

PCD tools is still in its infancy. The fl ex-

ible laser production system EWAG

LASER LINE for complete machining of

tools in a single clamping has been sup-

ported throughout its development by

the Institute for Laser Technology and

Systems Engineering of the Technical

University Hamburg-Harburg. The

Körber Group continues to collaborate

with the institute (see page 11), even

beyond this project.

Cold ablation

‘Today’s laser production systems are

mostly equipped with conventional

solid state lasers or fi ber lasers. While

these nanosecond lasers are cheap to

buy, they suffer signifi cant process dis-

advantages,’ says Christoph Plüss. One

of these is the heat-affected area on the

workpiece. As all three aggregate states are present, the surface quality and edge

quality suffer. Especially the smooth transition between the diamond cutting

edge and the carrier material is diffi cult to realize. Cold ablation eliminates these

disadvantages through ultrashort pulse lasers or picosecond lasers (ps-laser),

as used in the EWAG LASER LINE. The combination of high pulse energy and

ps

ns

ns-laser regime

ps-laser regime

Laser show: Presentation of the LASER LINE at EWAG Demodays 2010

1 GW 1 GW 1 GW


short pulse duration leads to direct

evaporation of the material to be re-

moved without a thermal transfer

phase. As virtually no heat develops,

all the relevant side effects disappear,

for example changes to the microstruc-

ture or microcracks in the material. The

laser ‘cuts’ through grain boundaries

and produces surfaces of excellent

quality and supreme surface roughness

values (Ra) from 200 to 300 nano-

meters. This increases the service life

of the cutting edge of the tool, i.e. the

service life of laser-treated cutting

edges is two to three times longer than

ground cutting edges. The grinding

experts at EWAG machine cutting

edges and chip breakers of indexable

inserts made of super-hard material in

a single clamping and meet the increas-

ing demands made on complex tool

geometries and surface quality. The

EWAG LASER LINE produces PCD mill-

ing inserts, which previously required

three steps on three different machines

(machining external contours with wire

EDM, peripheral grinding and applying

the negative phases) – in a single step

and within ten minutes.

Clean and effi cient

The LASER LINE has a fl exible 5-axis

kinematics system which can be used to machine indexable inserts and rotary

tools. A simple clamping device is all that is required for force-free machining of

workpieces with lasers. The LASER LINE is also equipped with a mechanical

clamping device for machining more complex tools. A loading robot adaptable

to individual customer requirements ensures automatic workpiece loading and

unloading. The vapors produced during laser ablation in the LASER LINE are

extracted during the process and cleaned in several stages via dust fi lters, fi ne

particle fi lters and active carbon. The entire machine is also fully enclosed. The

LASER LINE is more effi cient than traditional grinding processes when used to

machine super-hard materials, as it requires neither coolant or coolant systems

nor any wear parts. Furthermore, the fi nished workpiece is free from oily coolant

and therefore absolutely clean and ready to use.

Outlook

To start with, the LASER LINE aims to prove itself in the indexable insert produc-

tion, where EWAG has already successfully implemented various specifi c applica-

C OV E R S T O RY

10 MOTION 01/11

Laser processing à la

EWAG: A PCD

indexable insert in a

vacuum clamping

system which can be

robot-loaded

Productive and precise:

Machining a 3D chip breaker

in CBN

Machining of chip breaker and cutting

edge in one clamping

Flexible 5-axis kinematics for broad

range of tools

Excellent surface quality with

picosecond laser pulses

Modern drive technology with

direct drives

Integrated workpiece handling with

6-axis robot

Software: LaserSoft for programming

contours and chip breakers

Compact machine footprint of only

fi ve square meters

EWAG LASER LINE

High-tech from Switzer-

land: The LASER LINE is the

compact laser processing

center from EWAG


11MOTION 01/11

tions. The next logical step is the rotary

tools segment. Dr Harald Gosebruch,

Head of Technology for WALTER and

EWAG, explains: ‘The broad range of

rotary tools available on the market

opens up specifi c areas of application in

this segment for the LASER LINE.

WALTER and EWAG will continue to

develop these technologies step by step

– in addition to existing processes. In our

role as system and solution providers,

this will enable us, to supply various ma-

chines for grinding, EDM processing and

laser processing, as well as measure-

ment technology and logistics for tool

processing – all from a single source.’

Optimum quality:

Laser-machined

cutting edge of a

PCD milling insert

Starting in the autumn of 2011, the Laserzentrum Nord (LZN), a new venture for the

Institute of Laser Technology and Systems Engineering (iLAS) of the Technical Uni-

versity Hamburg-Harburg, is to make the results of top-level research in the area of

laser technology available to small and medium-sized companies. 35 staff members

are going to undertake application-oriented research on models of production lines

and assembly lines and develop them. They will also assist companies to apply these

models in their own factories and train specialists in laser technology. The ceremony

for laying the foundation stone of the Center for Applied Laser Research and Training

took place in the fall of 2010 in Hamburg’s Bergedorf district. This puts the LZN in

close proximity to its most important industry sponsor – Hauni Maschinenbau AG.

The Körber subsidiary is contributing two million euros to the basic funding of the

LZN for the fi rst fi ve years. ‘Lasers are already well established in our company. We

also foresee several new possible applications for innovative laser systems and instal-

lations within the Körber Group which we want to develop together with the LZN,’

says Richard Bauer, CEO of Körber AG.

LASERZENTRUM NORD

…Christoph Plüss, Head of Research and Development at Ewag AG

MOTION: What is the significance of laser

technology in terms of tool manufacture?

Christoph Plüss: Laser processing of diamond

cutting edges is a technological quantum leap in terms of quality, productivity and

flexibility. It is a must for every tool manufacturer who wants to be able to succeed

in the marketplace of the future. Yet there are many challenges that still have to

be mastered.

MOTION: Can you elaborate on that?

Plüss: In particular the industrial use of ultrashort pulse lasers in the machine tool

sector is still largely uncharted territory. Even the manufacturers of laser sources

have little experience or knowledge in terms of processing strategies with pico-

second lasers and their specialties, i.e. burst mode. Here, we are still working in

the area of basic research – which makes things a lot more interesting

MOTION: In your opinion, what will the future hold for laser processing?

Plüss: At the moment, ultrashort pulse lasers are still very expensive but they will

become the preferred standard in micromachining. Their efficiency is going to

double every two to three years which will result in better performance and more

application fields. In my view, one of the biggest challenges will be to actively

integrate the laser into the process control. This in turn should allow us to adjust

the beam and pulse properties of the laser to the specific requirements of the task

in hand.

SHORT INTERVIEW

Three questions for…

Head of R&D at EWAG: Christoph Plüss


12 MOTION 01/11

T O O L S & T E C H N O LO GY

Competence center

for the automotive

industry: The shop

fl oor at SCHAUDT

MIKROSA

EVERYTHING FROM A SINGLE SOURCE

COMBINED COMPETENCE

The boom in Leipzig2010 was a particularly successful year for SCHAUDT MIKROSA. As part of a strong Group, the Leipzig-based company has secured a pleasing level of orders and has further strengthened its profi le through a successful transfer of knowledge.

The specialty of SCHAUDT MIKROSA

are customer-specifi c solutions.

Precisely these were in extremely high

demand in 2010. The company managed

to increase its market share signifi cant-

ly, mainly through innovative machine

concepts for processing camshafts.

‘More than 95 per cent of our machines

are equipped with an application,’ says

Paul Kössl, Sales and Service Manager

at SCHAUDT MIKROSA. ‘Not only do

our basic machines have to be of excel-

lent quality, but we also have to deveop

technologies to process the respective

workpieces,’ explains the 45-year-old.

Economic recovery

At the moment, SCHAUDT MIKROSA is

benefi ting mainly from the economic

recovery in the automotive and the

automotive supplier industries. Among

the key customers of the Leipzig-based

company are the world’s largest suppli-

ers of camshafts, roller bearing manu-

facturers and well-known car manufac-

turers. ‘In this sector, we have managed

to perfect our technologies to cover a

wide range of special applications, such

as the processing of camshafts,’ adds

Kössl. The company also scores highly in the area of centerless grinding due to its

sophisticated technology. ‘We were able to attract several new customers, thanks

to shorter cycle times,’ says Paul Kössl. SCHAUDT MIKROSA is committed to pro-

viding its customers with machines that produce parts at minimum unit cost.

Growth market China

Even though SCHAUDT MIKROSA supplies the majority of its machines to custom-

ers in Germany and other Western European countries, the Far East plays an ever-

increasing role, as just over one in three machines is sold to China. ‘In recent years,

we have invested a lot of time and effort in the Asian markets, in order to provide

a better service in this

region,’ explains Paul

Kössl. Our team in

China is particularly

committed and has

steadily built-up our

local presence. This

also includes a com-

prehensive range of

services. We are now

able to meet the in-

creasing demand in

Successful transition

Since 2010, SCHAUDT and MIKROSA machines have both

been manufactured in Leipzig.

The experts from Stuttgart came to Saxony.

The company has optimized processes and further

improved the layout of the 10,000-square-meter facility.

By the end of 2010, SCHAUDT MIKROSA had phased out

production in Stuttgart and integrated it into the Leipzig

facility without any delay in meeting orders.

Combining expertise for the automotive industry.

L_S.12-13_Schaudt Mikrosa_E.indd 12 20.04.11 17:41

13MOTION 01/11

ones to benefi t most from merging the sites, as all the company’s services are

going to be available from a single source. Paul Kössl explains: ‘We serve the same

customer base with both brands and operate in very similar business areas. By

restructuring, we are able to optimize synergies and, as a competence center for

the automotive industry, continue to be a reliable partner for our customers.’

Transfer of knowledge: SCHAUDT process developer Thomas Schierwagen (middle) instructing his new

colleagues Enrico Lange (left) and Lars Völkel at the controls of a CamGrind series machine

+ + + p a u l . k o e s s l @

s c h a u d t m i k r o s a . c o m + + +

w w w . s c h a u d t m i k r o s a . c o m + + +

FURTHER INFORMATION

this booming region better than ever

before.’

Successful knowledge transfer

The increasing collaboration within the

SCHLEIFRING Group also plays a big part

in the company’s success story. Further-

more, there is the successful transfer of

knowledge from the former SCHAUDT

site in Stuttgart to Leipzig. ‘As part of the

restructuring process, we were able to

convince the experts from Stuttgart of

the benefi ts of the Leipzig site,’ says

Kössl. ‘By the middle of 2010, we had

started the complete manufacturing and

commissioning of all our products here

in Leipzig. The support of our colleagues

from Stuttgart was absolutely vital in

this endeavor.’ The customers will be the

L_S.12-13_Schaudt Mikrosa_E.indd 13 20.04.11 17:41

14 MOTION 01/11

High-speed assembly:

The automotive

industry places heavy

demands on screws

Less wear: Thread rolling dies that are ground using

the BLOHM process have a longer lifespan


SPECIAL SCREWS

Every thread is possible

Sectors like the automotive or the aerospace industry require high-strength special screws. The powerful BLOHM PROFIMAT MT grinds the thread rolling dies required for their manufacture in almost any conceivable shape.

Screws rolled between thread rolling

dies are characterized by their ex-

ceptional strength, compared with

those machined by stock removal. ‘Dur-

ing the rolling process, the screw mate-

rial fl ows into the new shape which strengthens it even more,’ explains Arne

Hoffmann, application engineer at BLOHM JUNG. The screw structure is not

destroyed as it is with thread milling. The process also saves material and makes

chip disposal unnecessary.

The main users of rolled, high-strength special screws are the aerospace and

automotive industries. The latter in particular has another important requirement

with regard to the screws. The automated high-speed assembly requires self-

centering screws which need to be perfectly tightened even if the application

angle departs from the ideal. Some self-centering screws, for example those

produced under license from US company MAThread® (see page 15), straighten

themselves, even at a 15-degree misalignment.

For the fi nished screws to meet the highest demands, the thread rolling dies

have to be produced to the highest quality and accuracy. The basis for this is a

powerful profi le grinding machine such the BLOHM PROFIMAT MT, a suitably

L_S.14-15_Blohm_E.indd 14 20.04.11 17:47

15MOTION 01/11

PROFIMAT MT. To start with, the entire thread rolling die is given an entry profi le

during the fi rst pass. The actual screw thread profi le is then ground during fur-

ther steps. The exact interpolation of the four machine axes of the PROFIMAT

MT has a signifi cant infl uence on the quality of the rolling die profi le and ulti-

mately on the mass-produced screws. The user software has been developed

by BLOHM experts and ensures smooth operation. Workpiece geometries are

easily determined by sensible parameterization and the process is controlled

accordingly. The user-friendly operator interface is based on Microsoft Windows:

The operator can compile the entire grinding program step-by-step using pre-

defi ned program components. The software automatically scans all relevant

grinding parameters like feed or thread pitch. No matter how wide the range of

screw threads, there are infi nitely more thread rolling dies needed to manufac-

ture them. BLOHM JUNG develops the corresponding grinding software for

every type of thread rolling die and manages to fi nd suitable solutions for a

variety of challenges.

Profi le of thread rolling die: The transition is what counts Curved lead-in: Any thread rolling die can be ground with the right technology

+ + + d i e t h a r d . l i e s a c k @ b l o h m j u n g .

c o m + + + w w w . b l o h m j u n g . c o m + + +

FURTHER INFORMATION

MAThread®

The special two-part thread of MAThread® screws ensures that the screw aligns itself

correctly, even if inserted at an angle. Using MAThread® prevents assembly problems,

caused by inserting the screw at an angle, and eliminates the costs incurred due to

repairs, faults and production rejects. MAThread® screws are particularly suitable for

technically demanding assembly processes and make a sustainable contribution to cost

reduction. They have become the preferred standard component for most German and

US car manufacturers.

Self-centering: The screws can be perfectly tightened regardless of the application angle

profi led grinding wheel and grinding

software for a 4-axis continuous-path-

control system.

A die with two profi les

The grinding of thread rolling dies is

usually done in three steps. Rough

grinding is carried out twice, fi nish

grinding once. Depending on the size

of the workpiece and the profi le depth,

the number of processing steps can

vary. Rolling dies for the production of

self-centering screws differ from those

used for ordinary screws. They have

two different profi les – the entry profi le

and the actual screw profi le. The tricky

bit is that the profi les merge into each

other. ‘In order to achieve the transition

from one profi le to the other in a single

line, a single-tooth wheel was previ-

ously used. This would grind up to the

transition and then retract; the wheel

would change and continue with the

other profi le. A slow and error-prone

process,’ says Arne Hoffmann.

Individual software solutions

Nowadays, BLOHM JUNG grinds both

profi les with a single wheel on the

L_S.14-15_Blohm_E.indd 15 20.04.11 17:47

Diffi cult to machine: The

grinding experts from

Switzerland offer solutions

for steam turbine blades

16 MOTION 01/11


TURBINE BL ADES

MÄGERLE gets up steam

Modern high-power steam turbines contain increasingly tough materials that are therefore very diffi cult to machine. MÄGERLE is keeping pace with these high demands.

People are becoming more aware of

world climate change and are there-

fore calling more loudly for the careful

use of available resources. The rising

prices of fossil fuels are driving steam

turbine manufacturers to develop even

more effi cient installations. ‘Increas-

ingly tough materials are being used

in turbine construction,’ says Rainer

Hungerbühler, Head of Sales & Market-

ing at MÄGERLE. ‘Specifi cations for

accuracy and surface fi nish are becom-

ing more stringent, so more and more

manufacturers have moved to grinding blade footings instead of milling them.’

In addition, Hungerbühler affi rms that grinding these components only involves

a fraction of the tooling costs. The size of the ring surface at the outlet from the

last stage has a crucial infl uence on the effi ciency of the whole installation. There-

fore the longer the last stage blade, the more effi ciently the plant runs.

Enormous centrifugal forces

Rotor blades spin at 3,000 or 3,600 rpm about the axis of a turbine. They there-

fore have to withstand enormous centrifugal forces. For example, the force ex-

erted on a blade in the last stage of the turbine, measuring 1.4 meters long and

L_S.16-17_Maegerle_E.indd 16 27.04.11 11:49

weighing about 50 kilograms, is equiv-

alent to a weight of more than fi ve hun-

dred metric tons. The blade footings

must absorb these forces and transmit

them to the rotor. So as to transmit the

forces as uniformly as possible over all

the material of the blade footing, the

footing has tight tolerances for dimen-

sional accuracy.

High machining output,

great accuracy

The MGC-L-260.75.90 grinding center

from MÄGERLE achieves very high

metal removal rates with great accu-

racy thanks to its extremely rigid struc-

ture. The water-cooled 75-kilowatt mo-

tor provides the required drive. This,

combined with the high autonomy of

the grinding center, ensures that ma-

chining times are kept to a minimum.

Hungerbühler explains: ‘The MGC-

L-260.75.90 is based on the proven

MÄGERLE traveling column principle,

with frictionless hydrostatic wrapped-

around guideways (x- and y-axes).

These ensure a very smooth running,

stable machine with vibration damping and high table loading capacity.’ The

console is mounted onto the machine bed and takes the clamping equipment

for the blades that are to be machined. An additional rotary axis (b-axis) can

be mounted onto the console if desired. This axis, used with the automatically

changeable measuring probes, enables the blade set-up to be automated with

a considerable reduction in setup time.

Quick change

The coolant nozzle built onto the grinding spindle can be programmed to move

into any desired radial position. The coolant is thus ready for use in the right place

every time. In addition, the machine has an automatic balancing system inte-

grated in the fl ange. A practical note: a rapid 4-compartment magazine for grind-

ing wheels and measuring probes ensures short machining times and permits

unsupervised operation. The ability to change wheels quickly and easily provides

the versatility needed for machining different

profi le geometries. This is a distinct advan-

tage, for example where internal and external

profi les do not match each other.

17MOTION 01/11

The MGC-L-260.75.90:

Even the largest workpieces

can be machined with

excellent results

Precision at the press of a

button: The grinding center

is based on proven

MÄGERLE technology

FURTHER INFORMATION

+ + + s a l e s @ m a e g e r l e . c o m

+ + + w w w . m a e g e r l e . c o m + + +

‘The MGC-L-260.75.90 is based on the proven MÄGERLE traveling column principle, with frictionless hydrostatic wrapped- around guideways’

Rainer Hungerbühler, Head of Sales & Marketing at MÄGERLE

L_S.16-17_Maegerle_E.indd 17 27.04.11 11:49

M O T I O N S & M O R E

Frank Ohmenzetter is a part of SCHAUDT MIKROSA’s history. He worked for the company for about 40 years – 20 years before the Wall came down and 20 years after-wards, some of them abroad.

São Paulo: The Brazilian

metropolis was Ohmenzetter’s

home from 1977 to 1984

PORTR AIT

A lifetime of service with MIKROSA

August 31, 2010 was a day Frank

Ohmenzetter will probably never

forget. ‘For me it was the icing on the

cake at the end of my career with the

company. Nothing like it had ever hap-

pened to me before,’ enthuses the

63-year-old as he remembers his offi cial

leaving party at SCHAUDT MIKROSA.

More than 100 guests came to say

goodbye to him after his long years of

service, including many longstanding

customers, who have become person-

al friends. The party marked the end of

a long, successful and eventful career

for the engineering graduate, spanning

39 1/2 years.

Seven years in Brazil

This kind of company loyalty is becom-

ing increasingly rare. Ohmenzetter,

who started working for MIKROSA as

a development engineer in 1971 fol-

lowing his mechanical engineering

degree, moved via investment plan-

ning into sales, where a real dream

job awaited him.

‘From 1977 to 1984 I worked as a sales

engineer in Brazil,’ he recounts. ‘That

was an extremely interesting time for

me and my family. The contrast be-

tween the socialist GDR and the “de-

veloping country” that Brazil was at the

time could not have been greater and is diffi cult for most people to imagine now.

The experience I gathered in those years had a big infl uence on my later career.’

Most important deal

In 1984 the family returned to East Germany and Ohmenzetter worked his way

up the company, reaching the position of Deputy Sales Director by the time the

Wall came down. With reunifi cation, things at fi rst looked critical: ‘MIKROSA

would not have survived that time without the SCHLEIFRING Group,’ he says.

For Frank Ohmenzetter, this turning point in the company’s history coincided

with an outstanding business deal: ‘I sold two centerless external cylindrical

grinding machines to Mercedes-Benz,’ he says, remembering every detail. This

deal with the Stuttgart-based car manufacturer is still the most important deal

Ohmenzetter negotiated for the company. ‘Then there came one follow-up order

after another from Volkswagen, Ford, TRW, BMW and others.’

Today he has no concerns about the future of SCHAUDT MIKROSA: ‘The com-

pany is in a very good position, offers a broad range of products and has a strong

leadership,’ says the former sales manager. Although he still has a keen interest

in the company’s progress, hav-

ing taken early retirement, he will

be following it largely from a dis-

tance in future. He hopes to stay

healthy because he and his wife

have a lot of dreams they want

to pursue in their newly acquired

free time. For instance, they have

never been to New York.

18 MOTION 01/11

PERSONAL DATA

Frank Ohmenzetter was born in 1948 in Püchau in Saxony (about 25 km east of Leipzig). Today, he lives with his wife Martina in Leipzig. They have a grown-up daughter.

L_S.18-19_Portraet_E.indd 18 20.04.11 17:53

19MOTION 01/11 1919119191919199191919919919919911999999TMOTMOTMOMMMOTMOTMMMMOTMOTOTMOTMMOTMOTMOTMOTMOMOTTMOTOTMOMMMMOTOTOTTMOTMMMOTMMMOMMMMMMOTMOMOTOTMOTTTMMMMMMMMOOOOTOTMOTMMMMOTMMMOOOTTMMMMMMMMMMMMMM TTIOIOIOIOIONONIOOOOOOONNOONONNNNNNIOIOOOOOOONNNNNNNIOIOIOOOONNNNNNNIOOOONNNIOOONNIOIIOOOOONNNONIIONNION 00000010101011111000101110 0001 001 0 0000 0000 0 00000001000 ///11/11/1//1/1/1//1/111/11/111////11/1/11/1/1/11/1111/////111/11111///11//11111/11/11/111/////11/111///11/1/11/11111////// 1111111199191991919199119999199919919919191919199919MOTMOMOTMOTMOTMOTMOTMMOTMOTMOTOMMOOOOTOTOOTOOOOOOOOTOTMOTMOTMMOMOTMOTMOTMMMMOOTOTOMOMOMOTMOMOTMOTTOTOTMMOMMMMMOTOTOTMOTOTMMOTMMMMOTMOTMMMOTOOTOTTMOTTMMMMMMOTOTOTOTMOTMOTMOTOTOTOTMMMOTMMOTOTTOTTOTTOTM TMMMOTOMOTOOTTTMMOMOTTMMMMOTOOTIONIOIONOOOOONNNIONIONIONNNNIONONONNNNNNNNIONIIONOOOONONONIONNNIONIONIOOOOIONNIONNNIONONONONONOONONONNIONONONOONNNNNNNNIONOOIONNNNNNNNNIONIIONOOOOOONNNNNNNIONIOOOOOOOOOOIONNNIOIOOOOOOOOONNNIIOOOOOOOOIONNIIOOOONNIOONIOOOOON 0101010101010101000111010100000000101010100101010101010010001000010000001/11/11///1/1/11/1111111//1///1111/1/11111///11/111/111/11111/11/11/11/1///1/11111111/1/1//11111/1111//11/111/11111///1111111/111///////111/11//////1111/1111/11/////1111111/////1/11111////////111/ 1

sharp by nature

www.meister-abrasives.com

L_S.18-19_Portraet_E.indd 19 20.04.11 17:53

20 MOTION 01/11


AEROSPACE

Reach for the stars with WALTER

Mitsubishi Heavy Industries is the market leader in the Japanese aerospace industry. The company came across WALTER machines a few years ago.

Space fl ights are technically very

challenging missions. Every single

component must work perfectly and

must be of superior quality. The aero-

space experts at Mitsubishi Heavy

Indus tries (MHI) have been aware of this

for some time. The Japanese company,

whose plants have been unaffected by

the severe earthquake on 11 March, sup-

plies the Japanese government with

rockets. MHI also manufactures jet en-

gines for Pratt & Whitney, Rolls-Royce

and the Japanese space agency Jaxa. ‘Our engines are used in large Boeing and

Airbus jets. The quality has to be right – the same applies to space rockets. Noth-

ing is left to chance,’ says Takaoki Niwa, Vice President and Deputy General

Manager of Mitsubishi Heavy Industries.

Flexible and versatile

In order to ensure the highest quality of the manufactured components, Mitsubishi

relies on WALTER technology. ‘We use different tools for each component. WALTER

machines are suffi ciently fl exible to allow the manufacture of these different

Off into space:

Japanese

astronaut

L_S.20-21_Walter_E.indd 20 27.04.11 11:49

instruments,’ explains Niwa. ‘We also

value WALTER’s fast and hassle-free

service,’ adds Production Manager

Hiroaki Takahashi. The Japanese com-

pany also uses the machines of

the grinding machine experts from

Tübingen to manufacture and sharpen

drills and end milling cutters. They are

put to use both in-house and by associ-

ate companies. ‘Aerospace components

have very tight tolerance requirements

– we are venturing into the micrometer

range here,’ says Takahashi. ‘Therefore,

we need machines that can cope with

these high demands.’

Software as an added value

WALTER has supplied Mitsubishi Heavy

Industries with a HELITRONIC POWER,

a HELITRONIC BASIC and a HELICHECK

PRO-type measuring machine. Niwa

and Takahashi value the high reliability

of the machines ‘Made in Germany’. The user-friendly software offers additional

benefi ts. Apart from WALTER machines, the Japanese company also owns sev-

eral other machines manufactured by members of the SCHLEIFRING Group: for

example, in September 2009, Mitsubishi Heavy Industries purchased two S30

cylindrical grinding machines from STUDER.

A strategic partner

The Japanese industry giant is aiming to double its market share of jet engines for

commercial aviation in Japan within

the next ten years. Currently, this

amounts to 31 per cent. As a result, the

company is going to need an increasing

number of high-precision and highly

effi cient tools during this period.

‘WALTER is a strategic partner to MHI,

and we very much enjoy working with

them,’ says Takaoki Niwa.

21MOTION 01/11

Dominated by the three diamonds: MHI offi ce building in Aichi

Meeting face-to-face: (from left) Hiroaki Takahashi, Siegfried Knüpfer, Managing Director of WALTER, Takaoki

Niwa and Christian Dilger, Sales Manager at WALTER

+ + + c h r i s t o p h . e h r l e r @ w a l t e r -

m a c h i n e s . d e + + + w w w . w a l t e r -

m a c h i n e s . c o m + + +

FURTHER INFORMATION

VISITING

WALTER attends Mitsubishi

Getting to know each other locally:

Managing Director of WALTER, Siegfried

Knüpfer and Sales Manager Christian

Dilger went to Japan in September 2010.

Together with Yuji Nakamura, Managing

Director of Walter Japan K.K., they visited

the Mitsubishi Heavy Industries factory in

Aichi. The grinding machine experts from

Tübingen set great store by taking special

care of major international customers like

MHI as part of a global partnership.

Part of the ISS space

station: The Japanese

experiment module Kibo

L_S.20-21_Walter_E.indd 21 27.04.11 11:49

As part of a BBC study, people from 27 countries have once again voted Germany the world’s favorite nation. MOTION introduces the country in the heart of Europe.

Symbol of unity: Until

1989, the Berlin Wall

was adjacent to the

Brandenburg Gate

which were often at war with one another. After the fall of the Iron Curtain, 21 years ago, all Germans were able to live together in a stable democracy for the fi rst time ever. For this reason, the National Day of Reunifi cation – October 3, 1990 – is such a special date for many people in Germany. As a sporting symbol of German unity, footballers from the East and West together also won the world championship title as one national team in 1990.

Almost anywhere in the world, Ger-many is known as the ‘nation of

poets and thinkers’. The phrase was coined by the writer Wolfgang Menzel. Yet when he wrote these words in 1828, Germany existed merely as a name for an area where German was the common language. For centuries, Germans were spread across up to 150 small states,

COUNTRY SPECIAL: GERMANY

Home of thinkers and inventors


22 MOTION 01/11

L_S.22-25_Deutschland_E.indd 22 21.04.11 09:10

[1] World heritage site on the Rhine: Cologne Cathedral, [2] Bavarian fairytale: Neuschwanstein Castle, [3]

Gateway to the world: Hamburg harbor at dusk, [4] Jewel on the banks of the Elbe: Dresden’s Semperoper

been restored to their former glory and attract tourists from all over the world. Large cities like Berlin, Hamburg, Cologne, Munich and other regions of Germany are enjoying ever-increasing popularity. Last year, approximately 3.2 million visitors from abroad stayed in accommodation between Flensburg and Garmisch-Partenkirchen. Germany is now the second favorite travel des-tination in Europe after Spain.

Positive Image

It seems that many people, who have never been to the Federal Republic, have a very positive image of the homeland of the Germans. As part of a survey by the British BBC World Ser-vice which was held this year, Germa-ny was once again voted the world’s favorite nation by 29,000 respondents from 27 countries. ‘As far as lifestyle is concerned and with regard to its

23MOTION 01/11

[1

Major achievements

The fact that the Germans have been pulling in the same direction in eco-nomic terms and are accomplishing considerable achievements together is shown in the diffi cult rebuilding pro-cess of the East German industry and infrastructure in the wake of the col-lapse of the socialist planned economy. According to calculations by the Free University of Berlin, West Germany has invested some 1.6 trillion euros in East Germany since the reunifi cation. Today, one cannot fail to notice the re-sults of this enormous investment. Nowhere else in Germany will you fi nd motorways, power lines, phone lines and a rail network as modern as in the fi ve new federal states.

Magnet for tourism

The impressive Baroque buildings in Potsdam and Dresden have once again

[1][1]

[3][3]

[2][2]

GERMANY IN BRIEF

Population: 81.8 million (2010)Capital: Berlin Currency: EuroGDP: 3,344 billion US$

(2009, nominal)GDP per capita: 40,780 US$ (2009,

nominal)National Language: GermanArea: 357,111.91 km²National holiday: 3 October (Anniver-

sary of German Unifi cation)

Berlin

[4][4]



24 MOTION 01/11

most important customers were France, the US and the Netherlands. German machine tools were once again among the most successful export products. Producers were able to sell machines, parts and accessories to the value of more than six billion euros to customers all over the world. Germany’s big success as an export nation is mainly due to the fact that local manufacturers have always known how to impress their customers with supe-rior product quality and new technologies. Many things that are a fi rmly estab-lished part of everyday life around the globe can be traced to fl ashes of inspira-tion by German boffi ns, engineers and scientists (see info box above). They show that Germany is not only a nation of poets and thinkers but also a nation of clever inventors.

high-quality products Germany has a very successful image,’ explains a spokesperson for the international poll-ster GlobeScan.

Boffi ns and inventors

Export statistics also show that Ger-man goods are popular all over the world. During the past year, the Fed-eral Republic exported goods to the value of 959.5 billion euros. The three

GERMAN INVENTIONS

So

urc

e: I

nit

iati

ve „

Par

tner

fü

r In

no

vati

on“


Approximately 60,000 patent applications are fi led ev ery year in the Federal Republic. MOTION presents some of the greatest German innovations.

Printing, Johannes Gutenberg (1440)

Beer, Duke William IV of Bavaria (1516)

Dynamo, Werner von Siemens (1866)

Automobile, Karl Benz, Gottlieb Daimler (1886)

X-ray technology, Wilhelm Conrad Röntgen (1895)

Spark plug, Robert Bosch (1902)

Cemented carbide, Karl Schröter (1923)

Television, Manfred von Ardenne (1930)

Magnetic levitation train, Hermann Kemper (1934)

Helicopter, Henrich Focke (1936)

Jet engine, Hans von Ohain (1936)

Computer, Konrad Zuse (1941)

Scanner, Rudolf Hell (1951)

Chip card, Jürgen Dethloff, Helmut Gröttrup (1969)

Airbag, Mercedes-Benz (1971)

MP3 format, Fraunhofer-Institute (1987)

Lübeck landmark: The

Holstentor on the edge of

the historic old town

SMALL GUIDE TO BUSINESS ETIQUET TE

Making a good impression in Germany

The international business commu-nity sets great store by profession-

al and exemplary conduct. Mistakes can quickly become a stumbling block in a foreign culture. MOTION gives you an overview of the most important forms of social etiquette in Germany.

In general: In German business situa-tions, personal relationships have very little infl uence on business relation-ships. You should therefore emphasize your professional competence as much as possible. Communication is normal-ly serious and formal but direct. Avoid

strong exaggerations and displays of emotion as they may be met with skepticism.

Greetings: It is customary to shake hands. When welcoming your counter-part, walk towards them; this signals openness and respect.

Appointments: Punctuality is a classic German virtue. Be sure to keep appoint-ments at all costs. If you expect to be delayed, call ahead of the time agreed with your business partner and offer a good explanation.

Eating and drinking: When eating out at a restaurant, it is customary for everyone to start eating together. If the food is not served at the same time, you should con-fer with your companions. A tip of ten to 15 per cent of the total bill is expected.

Don’ts: The informal ‘Du’ is relatively unusual in a business relationship, as is the use of fi rst names. Address your counterpart formally as ‘Sie’ and refer to them as ‘Frau’ or ‘Herr’ followed by their surname. In a business situation, the right to offer the less formal ‘Du’ is always reserved to the superior.

[1] Nation of car manufacturers: Final assembly of a VW Golf in the Wolfsburg factory

[2] Export success: Aircraft production at EADS Airbus in Hamburg-Finkenwerder

[1][1] [2][2]


Gauging and control for grinding machines

Absolute measuringsystem for parts with a large measuring range

Leading...

Please visit our website where you will find more detailed information and your nearest Marposs office.

www.marposs.com www.marposs.de www.marposs.ch

...results from the perfect combination

of many factors

Acoustic sensors for grinders

Grinding wheel balancing systems


It’s coming around again: The leading trade fair in our sector, the EMO, will be held in Hanover in September 2011. The SCHLEIFRING Group will also be participating with its prod uct presentations.

The venue for EMO 2011:

The Hanover Exhibition

Center

EMO 2011

At the leading trade fair

26 MOTION 01/11

Awhole series of innovations will be presented by the SCHLEIFRING

Group at this year’s EMO. These will include world fi rsts, such as the EWAG LASER LINE, the BLOHM ORBIT 25P and the STUDER S41. Here we give you a quick preview of the machines from our Group that you can see in the Hanover halls from September 19 to 24.

EWAG L ASER L INE

Milestones in laser technologyConcentrated light for the best machining results: The newly-developed EWAG LASER LINE sets new standards for the laser cutting of super-hard materials. It has the very latest laser technology, enabling external contours and the chip breaker to be produced without the need for re-clamping. A picosecond laser guarantees an ex-cellent surface finish together with particularly clean machining. With its 5-axis kinematics, the LASER LINE is suitable for a wide range of tools.

WALTER HELICHECK PLUS

The fi nest in metrologyThe HELICHECK PLUS from WALTER is a measuring machine for full non-contact measurement of precision tools, rotation-ally symmetrical parts and grinding wheels. It is even suit-able for measurements in the micro range, thanks to its second optical camera with 400× magnifi cation. A ‘cutting

edge rounding sensor’ is also available as an option,

enabling accurate and micro-precise measure-ment of surface and con-tour cut rounding on cut-ting tools. Longitudinal measurement error is E1 = (1,4 + L/300 mm)μm (to VDI/VDE 2617).

TOOL GRINDING

www.schleifring.net


A bundle of power:

Machining with lasers

Accurate measurement: The HELICHECK

PLUS for contactless measurement

L_S.26-29_EMO 2011_E.indd 26 21.04.11 18:05

Productivity,

precision and

fl exibility: The

HELITRONIC VISION

from WALTER

27MOTION 01/11

WALTER HELITRONIC V ISION

First choice for tools

The name HELITRONIC is internationally associated with top-level engineering in tool grinding. Within the family of products, the WALTER HELITRONIC VISION is once again the fi rst choice for the high-precision production of rotation-ally symmetrical tools and production parts from carbide, high-speed steel, ceramic, Cermet and CBN. With the op-tional magazine feeder and wheel changer for up to 36 grind-ing wheels, the HELITRONIC VISION offers increased pro-ductivity, particularly when grinding very complex geometries and for high-volume production.

EWAG INSERT L INE

Speedy and versatile

The EWAG INSERT LINE is the new high-speed grinding center for the extra-high precision peripheral grinding of tool inserts. Production time is up to 50 per cent shorter compared with conventional processes. In addition, the machine achieves extremely high form precision and cut-ting edge quality. Its outstanding features also include the latest ProGrind software and a Fanuc robot. The use of 350 to 500-millimeter grinding wheels ensures that all the requirements for cost-effective production are satisfi ed.

EWAG COMPACT LINE

Compact and ergonomic

The EWAG COMPACT LINE sets the standard for machin-ing indexable inserts from carbide and super-hard mate-rials such as CBN and PCD. Although compact, this ma-chine has no diffi culty machining external geometries with undercuts or chip breakers. It only takes a few minutes to retool it with a different clamping system, for instance clamping station, clamping yoke or nail clamping system. Another advantage of the machine is its ergonomic op-eration. A Fanuc robot means that both short runs and large batches can be produced economically.

27MOTION 01/11

Ideal for micro-tools: The

HELITRONIC MICRO

Resetting in a few minutes: The

COMPACT LINE is ideal for inserts

Grinding at high-speed:

The INSERT LINE from EWAG

WALTER HELITRONIC MICRO

Short changing times

The HELITRONIC MICRO is an automatic 6-axis CNC tool grind-ing machine specially designed for the complete machining of the challenging geometries of micro-tools. It gives the most accurate grinding results for diameters ranging from 0.5 to 12.7 millimeters. The integral robot loader has a capacity of 1,500 tools and reduces loading times to a minimum. Long, very thin workpieces are guided on a shank steady / support with fi ne adjustment.

Pro

prec

fl ex

HEL

from

L_S.26-29_EMO 2011_E.indd Abs1:27 21.04.11 18:05


28 MOTION 01/11

STUDER CT960

A talent for internal grinding

The CT960 is a high-end universal internal cylindrical grinding machine with a b-axis that can swivel up to 91 degrees and a 4-spindle revolver. It is suitable for both general grinding jobs and also, spe-cifi cally, the grinding of complex workpieces in tool making. The machine’s optimal stability and rigidity mean that work-pieces with polished surface fi nishes can be ground. The user-friendly HMI-SimCT programming and simulation software minimizes the programming and set-up times required for complex workpieces. The manual a-axis with helix angle adjustment ensures precise thread grinding.

STUDER S33

The reasonably priced one

The reasonably priced S33 is designed for the grinding of medium sized work-pieces, either individually or in small- or large-batch production. It can be au-tomated, and is particularly suitable for use in tool making and precision engi-neering. A new wheelhead with two motor spindles for external grinding and

an internal grinding attachment ensure that the workpiece can still be machined individually, but at greater speed. The S33 has by far the longest grinding length in its class.

STUDER S22

The production platform

High-quality guideway systems, short reaction times and optimized traverse paths are the basis of the S22 production platform. Its focus is on medium-sized workpieces in mass production. The machine technologies are conventional cylindrical grinding, profi le, thread and high-speed grinding (HSG) including heavy-duty applications with 160-mil-limeter wide grinding wheels. The x- and z-axes are in a cross slide confi gu-ration, while the work table is securely bolted to the machine.

ing

universal machine withto 91 degrees is suitable forand also, spe-

mplex workpieces ne’s optimal stability and rigidity mean that work-

Universally

applicable: The

CT960 from

STUDER

Production platform: The S22 is the machine of choice

for medium-sized workpieces in mass production

The reasonably priced S33 is designed for the grinding of medium sizepieces, either individually or in small- or large-batch production. It cantomated, and is particularly suitable for use in tool making and precisioneering. A new wheelhead with two motor spindles for external grind

an internal grinding attachment ensure workpiecstill be maindividuaat greaterThe S33 far the lgrinding leits class.

Versatile: The STUDER S33

can easily be adapted for

new grinding tasks

All-rounder: The

versatile S41 from

STUDER

STUDER S41

A world fi rst from Thun

The new STUDER S41 is a CNC universal cylindrical grinding machine designed for complex tasks. It is full of engineering refi nements such as the patented StuderGuide® guideway sys-tem, high-precision axis drives with linear motors and an ex-tremely fast direct drive for the b-axis. On top of this, there is an even greater selection of grinding head variants. This makes

the new S41 a true all-rounder for complex grind-

ing jobs.

CYLINDRICAL GRINDING

Combined processing: The S242 is

suitable for many batch sizes

A

ve

S

y pan even greater selection of grinding head variant

the new Sroco

STUDER S242

The

Flexible

The S242 combination grinding machine from the STUDER is an ideal combination of cy-lindrical grinding and hard turning technologies. Owing to its design, it can perform both operations with no compro-mises. For example, the S242 enables highly effi cient hard fi nishing of shafts and chucked components with high manufacturing quality and reliability, producing the required surface fi nish without any need to re-clamp. Furthermore, this fast machine saves up to 70 per cent machining time.

L_S.26-29_EMO 2011_E.indd Abs1:28 21.04.11 18:05

19-2

4.9.

2011

www.em

o-han

nover.d

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The world of metalworking

INFO:VDW – Generalkommissariat EMO Hannover 2011Verein Deutscher Werkzeugmaschinenfabriken e.V. · Corneliusstrasse 4, 60325 Frankfurt am Main, GERMANYTel. +49 69 756081-0, Fax +49 69 756081-74 · [email protected] · www.emo-hannover.de

SURFACE AND PROFILE GRINDING

BLOHM PROFIMAT MC-VS

Robust and reliable

Another highlight of the trade fair: The BLOHM PROFIMAT MC-VS, equipped with a fi xed or NC swiveling vertical spindle, permits internal and external circular grind-ing operations on rotationally sym-metrical workpieces, up to 1,000 mm in diameter. On top of this, the ma-chine can also accept profi le grind-ing jobs or curvic couplings. Its robustness, reliability and precision are crucial properties when it comes to economic production and the best possible quality.

MÄGERLE MFP-L-220.75.90

Powerful and versatile

The MFP-L-220.75.90 from MÄGERLE is a highly versatile, powerful and extremely precise surface grinding and profi le grinding machine with a 50-ki-lowatt horizontal spindle and a 20-kilowatt vertical spindle with HSK 63 loader. In combination with the indexing unit, it machines workpieces on fi ve sides with no need for them to be repositioned. The vertical spindle has an automatic tool changer for up to ten tools. As well as conventional surface and profi le grinding, the functions of the MFP-L-220.75.90 include measurement, milling and turning.

Profi table production in optimum quality:

The BLOHM PROFIMAT MC-VS

pfi le measurement,

A bundle of energy

from MÄGERLE:

The MFP-

L-220.75.90

L_S.26-29_EMO 2011_E.indd Abs1:29 21.04.11 18:06


In action:

Experienced ice

yachtsmen reach

speeds of around

130 kph

ICE YACHTING

Extra fi ne grinding for use on ice

Usually it is not BLOHM JUNG’s in-

tention to lead anyone onto thin

ice. In one particular case, however, this

was deliberate – and was crowned with

success, not least because of the 3-axis

PLANOMAT CNC grinding machine.

When Christian Seegers contacted

BLOHM JUNG in 2009, he wanted them

to grind the sharpest and consequently

the fastest blades. The 62-year-old has

a very unusual hobby. Whenever time

permits, the lawyer from Hamburg

visits the frozen lakes in the cold regions

of Europe and North America. He

whizzes across the icy surface with

speeds of up to 130 kilometers per hour.

In competitions, a race lasts up to 30 minutes – the biggest chal-

lenge is to allow the approximately 80-cm long, sharp blades to create as little

frictional resistance as possible on the ice.

Perfect for blades

In order to minimize the frictional resistance, Christian Seegers turned to BLOHM

JUNG for advice. The grinding experts knew at once which machine would do the

job: the PLANOMAT CNC. The series is renowned for incorporating proven and

innovative ideas in engineering technology such as the use of digital servo drives

with high-precision recirculating ball screws and linear guide ways on all axes.

Even in the basic version, the machine features linear measuring systems for y and

z-axes. Equipped with either a Siemens Sinumerik 840D or Fanuc control, dressing

and grinding programs are quickly adapted to the particular task. In this confi gura-

A clear run: The fast-moving sport is practiced on frozen lakes and rivers

30 MOTION 01/11

The PLANOMAT CNC from BLOHM JUNG has helped Hamburg ice yachtsman Christian Seegers achieve new performance levels.

L_S.30-31_Eissegeln_E.indd 30 21.04.11 09:42

Full speed ahead: High

velocities require a

high degree of

concentration from

the [email protected]

31MOTION 01/11

tion, the PLANOMAT CNC is ideal for fl exible and

profi table single-piece machining and batch produc-

tion. Equipped with acoustic sensors, the model is

particularly suitable for curved contours.

The crucial tip

One of the companies BLOHM JUNG has supplied

with a PLANOMAT CNC is Profi CUT Messertechnik

GmbH (PCM) in Solingen, Germany. PCM is also

using the machine to grind the blades of the Swiss

bobsleigh team and BLOHM JUNG suggested that

they would be the ideal contact for Christian

Seegers to talk to. Thanks to their high-precision

grinding effort, the Hamburg citizen got a good

headstart for subsequent competitions and is cur-

rently listed in 18th place in the international ice

yachting rankings. ‘At my age, you can no longer

expect to win at all cost,’ says Christian Seegers

humbly. His son Andreas, on the other hand, has

a good chance of winning races over the coming

years. He is after all following in his father’s foot-

steps and has also had the perfect blades ground

on the PLANOMAT CNC.

L_S.30-31_Eissegeln_E.indd 31 21.04.11 09:42

Optimum results: The S41

guarantees highest

surface qualities

32 MOTION 01/11


CYLINDRICAL GRINDING

New standard for qualityThe new S41 CNC universal cylindrical grinding machine grinds with even more preci-sion than its predecessor. Electric direct drives offer even more speed and preci-sion when approaching the grinding positions.

Shorter cycle times, greater preci-

sion, superior surface quality and

better metal removal rates – these are

just some of the ever-increasing market

demands on the effi ciency of grinding

machines. STUDER has developed the

new S41 CNC universal cylindrical

grinding machine with the aim of meet-

ing these requirements. The Swiss

cylindrical grinding experts have built

on the practical experience gained from

the machine’s predecessor which has

enjoyed worldwide recognition for

many years. The new S41 has an im-

pressive number of outstanding design

features. It also offers commercially vi-

able production possibilities for a

broader range of applications and by

cutting down on auxiliary times, grind-

ing process cycle times are shortened

considerably.

Using state-of-the-art technology

The machine’s predecessor has undergone continuous improvement since its

market launch 20 years ago, which ensures grinding at the highest technical

level at all times. As the trend towards even higher demands continues, STUDER

has developed a completely new machine concept for the S41. The Swiss cylindri-

cal grinding experts subjected the machine to 18 months of intensive testing – all

in all, the S41 has undergone more testing than an Airbus. STUDER sees itself

not just as a manufacturer of grinding machines, but also as a partner to its clients

in designing technically and economically optimized grinding processes. Grind-

ing workpieces effi ciently requires complete solutions optimized to your pro cesses.

This also includes integrated quality control through constant measuring, check-

ing, recording and adjusting. With the help of modular periphery equipment such

as loading and unloading systems, it is also possible to integrate workpiece

grinding seamlessly into the overall production process. The automation systems

of the periphery equipment communicate with the S41 via standardized inter-

faces, which can also be used to solve complex handling tasks.

Rigid machine bed

One of the special features of the new S41 is the more solid, more rigid and more

thermally stable machine bed made of Granitan® S103. Its physical properties

provide ideal operating conditions for grinding. The machine bed is designed to

L_S.32-33_Studer_E.indd 32 21.04.11 09:52

33MOTION 01/11

Complete machining made simple: Turret wheelhead with two external grinding spindles and one internal grinding spindle

All-rounder from Thun: The new S41 is highly versatile

+ + + m i c h e l e . f a h r n i @ s t u d e r . c o m

+ + + w w w . s t u d e r . c o m + + +

FURTHER INFORMATION

travel speeds of up to 20 meters per minute and axis system resolutions of ten

nanometers. This enables accurate and highly effi cient grinding while drastic-

ally reducing auxiliary times. The swivel movement of the turret wheelhead

(b-axis) is also controlled by a direct drive. This swivels the wheelhead around

three times faster than the machine’s predecessor while positioning new grinding

wheels in a shorter time with a positioning accuracy range of <1˝.

Wheelhead combinations for every application

Up to four external grinding wheels or three internal grinding wheels allow ev ery

possible wheelhead combination. The grinding wheels are no longer driven by

belt drives but by motor spindles only. The machine can also be equipped with

motor spindles for high-speed grinding (HSG). Internal grinding spindles with

speeds from 6,000 to 120,000 rpm can be fi tted. Fatigue-free working and straight-

forward machine operation are vital components for consistently high quality.

A single Allen key is all that is required to change the grinding wheel and a special

lifting device is integrated into the machine, so that heavy grinding wheels do

not have to be lifted manually. The S41 is fi tted with a Fanuc 31i-A machine con-

trol with integrated PC. The 15-inch touch screen makes intuitive operation and

programming easier. The StuderWIN operator interface creates a stable programm-

ing environment and contributes to the overall effi ciency of the machine.

offer a stable base for the integrated

guide system to absorb the high forces

that occur during grinding with high

metal removal rates. The new Studer-

Guide® guideway system ensures high

precision of the longitudinal slide and

the cross slide, both at standstill and

during travel. StuderGuide® combines

the advantages of hydrostatic and hy-

drodynamic guide systems and avoids

the slip-stick effect or fl oating of the

slide. The solid cast iron longitudinal

and cross slides rest completely on the

guideways over the entire travel range

and this also contributes to the ma-

chine’s high precision. With this main-

tenance-free guide system STUDER

guarantees a straightness of <0.003

millimeters over a measured length of

950 millimeters (0.004 milli meters over

1.550 (2 × l)).

Direct drives increase speed

and precision

The longitudinal slide (z-axis) features

a ground work table carrying the work-

head and tailstock with a center height

of 225 millimeters (275 millimeter as an

option). A ground T-slot over the entire

length of the table is designed to enable

optimal positioning of dressing tools.

Longitudinal slide and cross slide are

moved by linear direct drives, allowing

L_S.32-33_Studer_E.indd 33 21.04.11 09:52


Technical customer advisers from the SCHLEIFRING Group work actively to prevent wear. This not only saves time, it saves money too.

Keeping the

machines running:

Henry Donat from

Kessler and Rudolf

Pickel from STUDER

SERVICE IMPROVEMENT

Partner for customers

A true-life example: At the Franz

Kessler factory in Bad Buchau,

South Germany, Head of Maintenance

Henry Donat greets the STUDER im-

provement engineer Rudolf Pickel like

an old friend. The two men have been

working closely together for three years.

Service adviser Pickel helps the Swabian

company to keep its six STUDER ma-

chines running. This prevents unplanned

standstills and saves cash. ‘We want to

prevent wear,’ says Donat. ‘Where main-

tenance is concerned, STUDER offers a

full service.’ Franz Kessler’s employees use the Swiss machines to grind items such

as spindle shafts, bearing shields and release units for machine tool making.

Service brings reliability

For Donat, good service means one thing above all: reliability. This is the reason why

the 46-year-old sticks with STUDER. Dependability and accurate documentation are

other factors that keep him in regular contact with ‘his’ service adviser. There are

fi nancial reasons, too, for systematic maintenance. Donat says, ‘Training one’s own

people on the machines takes a lot of time. It is more effi cient for an expert to come

into the factory for a couple of hours at regular intervals and inspect the machines.

34 MOTION 01/11

An open ear: (from left) Sandro Bottazzo and Rudolf Pickel from STUDER with Henry Donat

L_S.34-35_Service Improvment_E.indd 34 21.04.11 18:06

35MOTION 01/11

MOTION interview with STUDER Service Improvement Engineer Rudolf Pickel and Daniel Grasser, Technical Customer Adviser at WALTER.

MOTION: How many customers do you visit in a year?

Pickel: 165 altogether. With follow-up time added to the on-site visits, I am

continually kept busy.

Grasser: About 120 in the last year, all over Europe. These also include a

lot of customers who have a number of WALTER machines.

MOTION: What does it take to be a customer adviser?

Pickel: I was a service technician for fi ve years. In 2005 they said: Rudi, you

have technical experience and you get on well with customers – would you

like to do this? Most of my customers are master craftsmen or department

heads with the same engineering background. They like it when they realize

that they are dealing with

someone who knows about

grinding.

Grasser: Exactly, I agree with

that. These are basic require-

ments for determining our cus-

tomers’ different needs and

then giving them comprehen-

sive advice.

MOTION: What is the appeal

of the job?

Grasser: Dealing with people.

Although technology is the ba-

sis for it all, every on-site ex-

perience is fascinating.

Pickel: Yes, people are the cru-

cial factor. As time goes on I get to know each of my customers better and

fi nd out the best way that I can support them.

MOTION: What added value does your work give to your customers?

Pickel: We are the human face of the SCHLEIFRING company. The customers

get a personal contact that they can turn to.

Grasser: Through the advice we give, which is not limited to just the grind-

ing machine, the customer learns how he can safeguard and optimize his

production. We see ourselves as supplying a system, because we offer

measuring machines and various other services such as networking in ad-

dition to grinding machines. So we bring our customers’ production to a

‘higher level’, so to speak.

Pickel: And sometimes we continue to support the customer within his

company. For example: A department head gets an order to optimize grind-

ing processes from his CEO. Instead of putting several hours’ work into this,

he rings me up and I quickly fi nd a suitable answer for him.

STUDER’s cost-effectiveness has com-

pletely convinced me of this.’ These main-

tenance visits are important to Donat

because Kessler grinds in the μm range.

‘This is why our machines always have

to be in tip-top condition,’ he says. For

Anton Mayer, CEO of Kessler, the name

STUDER stands for ‘high standards of

engineering, high precision, reliable ma-

chines and, of course, good service’

above all. In order to guarantee this,

SCHLEIFRING service advisers visit be-

tween 1,000 and 1,500 customers annu-

ally, as explained by Sandro Bottazzo,

Head of Strategic Marketing at STUDER.

Knowing each other

For Pickel, getting to know his customer

on site is indispensable. ‘Meeting per-

sonally saves time, as each one knows

what the other would like. We improve-

ment engineers see ourselves as our

customers’ partners,’ he says. He has

been touring southern Germany as a

STUDER service adviser since 2005.

When he leaves Franz Kessler’s factory

after an hour and a half, Rudolf Pickel is

content. Once more, he has helped a

customer. In six months’ time, Pickel will

visit the factory in Bad Buchau again. He

will be happy to advise Henry Donat

once more and show him possible pre-

ventive measures.

MADE-TO MEASURE SERVICES

Placing people at the center

Out and about for customers: Rudolf Pickel (STUDER) and

Daniel Grasser (WALTER)

FRANZ KESSLER

Portrait of a company

Franz Kessler GmbH in Bad Buchau main-

ly grinds high-precision components for

motor spindles, turntables, swivel axes and

inclinable spindle heads. Kessler is the

market leader in Europe for direct-drive

motor spindles. The fi rm’s principal cus-

tomers are from the machine tools sector.

Currently the machine factory, covering

25,000 square meters, has around 600

employees, including 70 trainees.

+++ sbot t a z zo@ sch le i f r i ng .ne t +++

r udo l f.p i c ke l@ s t uder. c om +++

dan ie l .g rasser @ wal t e r- mach ines .c om +++

FURTHER INFORMATION

L_S.34-35_Service Improvment_E.indd 35 21.04.11 18:06

36


MOTION 01/11

CONTINUOUS DRESSING

Ceramic grinding for the heartPaper-thin ceramic segments for ultrasound equipment help to eliminate cardiac arrhythmia. Thanks to JUNG technology, it is possible to machine them profi tably.

The heart is a natural miracle. It beats

continuously and automatically ad-

justs to different stress levels. But it can

also stumble and stutter. The cause of

such arrhythmia can be random electri-

cal signals generated by damaged heart

tissue. If left untreated, they can lead to

fatigue, stroke or even heart failure. The

condition is usually treated with drugs.

If it persists however, other methods

such as atrial fi brillation ablation by

means of high-frequency (HF) or high-

intensity (HIFU) ultrasound are neces-

sary. Both procedures are gentler on

the patient than the older, more radical

treatment methods. The latter required

the use of heart-lung machines to sup-

port life during an operation. The HIFU

or HF procedure transmits high-inten-

sity focused ultrasound or targeted

high-frequency signals in order to destroy the heart tissue that sends the irregu-

lar signals. During this procedure, a transducer remains strapped around the

heart, until the damaged heart tissue is broken down by ultrasonic pulses. After-

wards the heart beat should return to its normal rhythm.

The ceramic grinding challenge

Two wafer-thin, critically dimensioned ceramic parts are used in the transducer.

Up to 30,000 of these specialized parts are produced every year by B & H Techni-

cal Ceramics based in San Carlos, California. Nowadays, the company grinds

the individual segments from a solid ceramic blank on a JUNG surface profi le

grinding machine with a PA37K profi le dresser. At the beginning, Gunther Horn,

President and founder of B & H, was not sure whether the parts could be eco-

nomically produced in bulk. The dimensional tolerances amount to ±0.005 mil-

limeters. Average surface quality is ≤0.4 micrometer. Furthermore, Macor ceram-

ics and C5800 PZT, the ceramics processed, are the cause of extremely high

A matter of the heart: Ultrasound is effective against arrhythmia

Sensitive material: Wafer-thin ceramic parts for medical ultrasound equipment

L_S.36-37_Jung_E.indd 36 03.05.11 15:46

grinding wheel wear during

the grinding process.

An educational time

During the prototype pro-

duction, each workpiece

was fi rst ground carefully

by hand on a simple surface

grinder. This takes up to 60

minutes per segment. There

was a high number of re-

jects and the quality of the

fi nished components was

inconsistent. Yet the ex-

perts at B & H learnt a lot

during that time. They re-

duced the grinding time

many times over by using a vacuum chuck to fi x several work-

pieces to the grinding table at the same time and without any

deformation. They also optimized the composition of the

grinding wheel. The biggest challenge remained the continu-

ous alignment and resharpening of the wheel during the grind-

ing process. Horn asked United Grinding Technologies, the

SCHLEIFRING Group’s US competence center, for a suitable

machine. They forwarded the inquiry to JUNG, who quickly

found a solution in the PA37K profi le dresser which meets the

requirements of the Californian company perfectly. Thanks

to three programmable axes, they were able to adapt the

tangent point of the dressing tool ideally to the shape of the

grinding wheel.

GRIPS 32 programming system

A prerequisite for this is JUNG’s own GRIPS 32 programming

software. In just a few steps, geometries for profi le genera-

tion can be imported. The integrated collision control checks

the feasibility of the grinding task. The PA37K can be used

with static or driven dressing tools which it sets up auto-

matically. What convinced Horn in the end was the PA37K’s

ability for continuous dressing during the grinding process,

without interrupting cycle time. ‘Continuous dressing has

signifi cantly reduced grinding pressure during manufacture

and has allowed a higher infeed rate. Tooling costs have also

been signifi cantly reduced due to a driven dressing wheel

and increased service life of the dressing tool,’ explains Horn.

He was completely won over by the JUNG concept. To this

day, it guarantees a sound and effi cient production process

for ceramic parts. JUNG’s dressing technology combined

with Horn’s experience in

ceramic grinding ensures

operating cycles that are

as constant as a healthy

heart beat.

When clamping becomes critical …Extraordinary applications demand

extraordinary solutions. Many work-

pieces cannot be properly clamped

by virtue of their unique characte-

ristics. We develop targeted custo-

mized chucking systems.

FORKARDT SCHWEIZ GMBHIndustriestrasse 3, CH-8307 EffretikonTel. +41 52 355 31 31, [email protected] ITW Workholding Company

WWW.FORKARDT.CH Highest quality and precision within the m range

Gentle procedure: Heart patients benefi t

from high-intensity ultrasound (HIFU)

+ + + t h o m a s . l a s c h u e t z a @

b l o h m j u n g . c o m + + +

w w w . b l o h m j u n g . c o m + + +

FURTHER INFORMATION

L_S.36-37_Jung_E.indd 37 27.04.11 11:49

38 MOTION 01/11


Chinese metropolis:

Around 20 million people

live in the Shanghai

administrative area

CHINESE GROW TH MARKET

Near to customers in the Far East

Through its Chinese location, the SCHLEIFRING Group is close to its customers in one of the biggest, most important markets of the future.

Germany and China: at fi rst glance

the two countries appear very dif-

ferent, but after a few months in China,

Jürgen Schock is noticing some simi-

larities too. ‘When you live with the

people day in, day out, you start to

understand things that appear strange

at fi rst and discover the similarities,’

says Schock. He has been General

Manager of SCHLEIFRING’s Chinese offi ce, Körber Schleifring Machinery (Shang-

hai) Co. Ltd. (KSMS), since July 2010 and now feels quite at home there.

Tuned in to customer needs

Although there are lots of similarities, cultural differences remain and should

not be underestimated, even when it comes to production methods. Understand-

L_S.38-39_KSMS_E.indd 38 27.04.11 14:19

39MOTION 01/11

High-quality work

‘We manufacture our machines in strict compliance with European performance

and quality standards, even in China,’ explains Jürgen Schock. ‘This demands

a big investment in training skilled staff at all levels of the organization.’ The

requirements of Chinese customers are getting closer to European levels. KSMS

is designing its cylindrical and surface grinding machines to meet these more

stringent requirements and needs. The machines are confi gured and equipped

in consultation with customers and in line with their requirements – just as they

are in Europe. ‘Customers who buy our machines receive an extra level of serv-

ice: we give them the know-how they need to manufacture selected parts. 70

per cent of products leave our Shanghai plant with individual customer applica-

tions,’ says Schock.

KSMS is very committed to supplier training and invests a lot of effort in qual-

ity management and in monitoring the individual production steps. ‘We want to

offer our customers German effi ciency and Swiss precision in China and we’re

working hard to achieve this,’ says Schock. He has ambitious plans for the future.

For instance, he plans to achieve stable growth in the area of local products and

increase the SCHLEIFRING Group’s market share in sales of imported products

by expanding the company’s product range and strengthening its application

competence. ‘Many of our customers are active all over the world and expect

global support from us. They too benefi t from the SCHLEIFRING Group’s pres-

ence in China,’ explains Stephan Nell. ‘With our large KSMS sales and service

team we can now provide our customers in

China with even better support. This is where

our Group once again demonstrates its

strength by allowing us to achieve more to-

gether than we could individually.’

In-house production: Körber Schleifring Machinery ShanghaiI manufactures products

for the Chinese market

FURTHER INFORMATION

ing the differences requires direct

collaboration with customers on a dai-

ly basis. This need for customer prox-

imity in what is considered the world’s

most promising market is what prompt-

ed the Körber SCHLEIFRING to estab-

lish Körber Schleifring Machinery Co.

Ltd. in 2004. ‘Providing customers with

services in their country and in their

language is very important to us. This

is only possible if we are on the spot

and can develop an understanding for

our customers’ needs by dealing with

them every day,’ explains Stephan Nell,

a member of the KÖRBER SCHLEIFRING

Management Board. Initially represent-

ed in the Chinese market through vari-

ous sales offi ces, the group has now

started assembling machines at KSMS

and began manufacturing its own parts

as early as summer 2010.

Körber Schleifring GmbH’s decision to

start producing in China is in line with

the fi ndings of a recent study by Roland

Berger Strategy Consultants, which

found that European companies need

their own production facilities in China

if they are to remain active in the

Chinese market in the long term. Today,

KSMS employs 210 people, including

four German, two Swiss and one French

employee, and runs four sales and

distribution offi ces in Beijing, Chong-

qing, Guangzhou and Wuxi, in addition

to the Shanghai production plant.

About half of the employees work in

sales and service, while the remaining

50 per cent work in production and in

sourcing and development. Meanwhile

KSMS produces more than 100

machines locally each year. More than

90 per cent of

these are des-

tined for Chi-

nese customers

in the areas of

automotive sup-

ply, general ma-

chine construc-

tion and tool

manufacture.

+ + + J u e r g e n S c h o c k @

s c h l e i f r i n g . c n + + +

w w w . s c h l e i f r i n g . c n + + +General Manager of

KSMS: Jürgen Schock

L_S.38-39_KSMS_E.indd 39 27.04.11 14:19

ARCHERY

Following in William Tell’s footsteps


In his spare time, STUDER employee Hans Flühmann is a successful archer. In 2010, he even won the World and European Championships.

As taut as a bowstring:

Hans Flühmann takes aim

with his high-tech bow

William Tell himself would proba-

bly take his hat off at this level

of precision. Just as the fabled Swiss

national hero is said to have been a

crack shot with his crossbow, today,

around 700 years later, his compatriot

Hans Flühmann is doing the same with

a composite bow. ‘I’ve never had to

shoot an apple off anyone’s head before

though,’ says the 56-year-old, laughing.

Trophy hunter

Flühmann has good reason to be happy: 2010 was an extremely successful year

for the STUDER machine assembly technician. In May, he won the European

Championships, and three months later went on to become World Champion,

setting a new world record in the process. ‘The participants had to shoot a total

of 476 arrows over the fi ve days of the competition from a distance of between

six and 73 meters,’ says Flühmann, explaining how he won his championship title.

Concentration is everything: The 56-year-old focuses on the target

40 MOTION 01/11

L_S.40-41_Hobby_E.indd 40 21.04.11 15:23

On target: In outdoor

archery, archers have

to hit the target from

up to 90 meters away

Properly equipped: It is

important to have the right

arrows

Medal: Flühmann won 13 competitions

in 2010 alone

Swiss precision: The World

and European Champion

in action

41

made of carbon fi ber or aluminum. Indoor arrows are thicker – about 9 mm. Out-

door arrows are only about 5 mm thick, which means they are less likely to be

blown off course by the wind and makes them much faster,’ says Flühmann. The

thin outdoor arrows have a top speed of up to 330 kph, although only when a real

professional, like Flühmann, is drawing the bowstring.

‘At the end I had 546 points, which was

one more than the existing world record.

I couldn’t believe it.’ The STUDER em-

ployee from Hofstetten near Brienz still

speaks with pride and emotion about

his tremendous achievement.

Hooked

Flühmann’s great passion began pure-

ly as a hobby: ‘When I was young I made

a bow and arrow from hazel switches

and had competitions with my friends.

At that age, it was all about shooting as

far as possible,’ says Flühmann, recall-

ing his childhood. ‘I fi rst saw an archer

when I was 16. I was hooked and never

looked back.’ However, he didn’t take

part in competitions until the age of 44:

‘In my fi rst competition I had to make

do with coming second to last, but I won

the second one.’ What followed was a

success story pure and simple: in 2010

alone, Flühmann won 13 tournaments

in a wide range of competitions, includ-

ing numerous Swiss championships in

a number of different disciplines, as

well as the European and World Cham-

pionships. ‘There are lots of disciplines

in archery. I have won at least one Swiss

championship title in all of them.’ The

distances and targets vary. For instance,

in 18-meter indoor target archery, the

target is only 20 cm in diameter and the

central bull’s-eye is just 2 cm wide. For

the 90-m outdoor distance, the target

face is 120 cm in diameter. This requires

strength and stamina as well as accu-

racy, and Flühmann trains regularly to

build up both, as well as practicing his

shooting.

High-tech bow with

pulling power

Flühmann practices three or four times

a week. Today’s bows are high-tech

pieces of equipment. ‘My bow is a com-

pound bow,’ he explains. ‘The central

riser is made of machined aluminum

and the limbs are high-grade carbon

fi ber.’ The draw weight of a bow like this

is 60 pounds. There are also subtleties

when it comes to the arrows: ‘They are

MOTION 01/11

hans.fl [email protected]

L_S.40-41_Hobby_E.indd 41 21.04.11 15:23

42 MOTION 01/11


Richard Bauer, Chairman of the Management Board of Körber AG and Chair-

man of the Management of SCHLEIFRING, was delighted to welcome the

international guests to one of the most important STUDER events of the year and

to have an opportunity to present Körber Schleifring’s strengths: ‘The SCHLEIFRING

Group with its employees and contractors, its technology, its global sales and

service network, and its collaborative partnerships in the fi elds of technology

and beyond, is a strong group of companies.’ Some of the Group’s greatest

strengths, according to Bauer, are its worldwide presence, an almost complete

range of grinding technology from a single source, its technical expertise and its

exploitation of service opportunities. In addition, the SCHLEIFRING Group is al-

ways developing innovative new products, like the S41 (see page 32). The machine

was on display for a week in Viehmarktplatz, a market square in Thun.

The S41 goes on sale

The starting signal for sales of the new machine was given by STUDER’s new

Managing Director, Peter Weber. The 42-year-old studied technical management

and has been Managing Director of SCHAUDT MIKROSA since 2005. As of

January 2011 he is also responsible for service and sales at STUDER. ‘It’s a

challenge I am happy to take on,’ says Weber. The S41 was seen by sales rep-

resentatives and journalists from ten countries on the second day of the meet-

ing. During a tour of the STUDER headquarters in Thun they were given an

opportunity to marvel at BMX riders jumping over the machine. There was also

a sporting theme to the closing Surprise Night, when the participants rode

‘velogemels’, wooden snow bikes, down the Männlicher, a 2,000-m peak near

Grindelwald. By contrast, STUDER is set

to keep on going up, and the company

has already laid the foundations for its

future growth.

+ + + m i c h e l e . f a h r n i @ s t u d e r . c o m

+ + + w w w . s t u d e r . c o m + + +

FURTHER INFORMATION

Giant leap: A BMX rider jumps over an S41 during the

visitors’ tour

Surprise Night: Guests rode down the mountain on velogemels, a type of wooden snow bike

A laser projection on the Swiss Alps: The S41 is the global innovation from STUDER

New board member at STUDER: Peter Weber

MOTION MEETING

The MOTION MEETING is held at the end

of January each year in Thun, Switzer-

land, and is a highlight of the STUDER

calendar. It is a chance for staff to meet

sales representatives from all over the

world who ensure that the Swiss

company’s cylindrical grinding ma-

chines are available right around the

globe. The grand fi nale is always the

traditional Surprise Night.

id j ps over an S41 during the

STUDER MOTION MEETING

People and machinesThis year’s MOTION MEETING held some surprises in store, the fi rst of which was the latest STUDER machine. But there was news on the personnel front too.

L_S.42-44_Meeting_News_Adressen_E.indd 42 27.04.11 12:02

43MOTION 01/11

For shafts that require high run-out tolerances between

outer and inner diameters, the design of the work holding

presents a considerable challenge. The usual method is to

perform all of the external grinding operations between

centers in an initial stage. This is followed by internal grind-

ing, for which the universal grinding machine needs to be

retooled and fi tted with a fi xed steady. In addition to the time

needed for retooling, the disadvantages of this method are

that either there are unwanted marks from the steady, or an

additional bearing point has to be ground. Again, the point

at which the workpiece rests on the mounting can be in an

awkward location, depending on the outer contour of the

workpiece. In this case, the piece may have a long unsup-

ported length and become unstable for internal grinding.

STUDER has found a way around this problem with a hollow

center tailstock. This enables external and internal grinding

to be done without the need to re-clamp. This saves the

operator valuable time. There is also a marked improvement

in concentricy. Deep bores can be machined from both sides

using a much shorter grinding tool. The hollow center

tailstock guarantees a stable mounting and a quick, safe tool

change.

Offering stability with no overhang: The STUDER hollow center tailstock

HOLLOW CENTER TAILSTOCK

Clamp just once

SOF T WARE

HELITRONIC TOOL STUDIO

NEWS TO USE

Practical tips for productionIdeally, grinding processes require suitable machine parts and supporting software. STUDER has a new hollow center tailstock that meets the fi rst requirement, while the second is met by the latest version of the HELITRONIC TOOL STUDIO software from WALTER.

[email protected]

Now even more versatile: Version 1.9 of the HELITRONIC TOOL STUDIO

grinding software offers new functions, such as integral loader control,

IMS, negative chamfer on face and profi les, faceting, Reapply Wizard for

mills and automatic wheel examination on the HELICHECK measuring ma-

chines and also new options for producing drills. The new ‘Wheel shape’

chip space calculation enables the operator to design the chip space indi-

vidually. The corresponding wheels are automatically calculated. The forms

supported are J and DXF. In order to make the drill production process even

better, WALTER has developed the automation over-table, which can be

operated in TOOL STUDIO 1.9. A variety of extensions can be added to this,

such as a tailstock or an Arobotech steady rest. In addition, it is now pos-

sible to control the dressing process via the TOOL STUDIO interface so as

to maintain the shape of the grinding wheels and achieve the best possible

grinding result. The update is suitable for all HELITRONIC models.Software for many applications: WALTER HELITRONIC TOOL STUDIO, Version 1.9 [email protected]


Körber Schleifring GmbH

Nagelsweg 33–35

20097 Hamburg

Germany

Phone +49-40-21107-03

Fax +49-40-21107-13

[email protected]

www.schleifring.net

Körber Schleifring Machinery

(Shanghai) Co. Ltd.

1128, Taishun RoadArlington TownShanghai Jiading 201814,ChinaPhone +86-21-395873-33Fax [email protected]


(Shanghai) Co. Ltd.

Beijing Branch Offi ce

Room 10-04, CITIC Bldg.19Jian Guo Men Wai Da JieBeijing 100004, ChinaPhone +86-10-659599-34Fax [email protected]


(Shanghai) Co. Ltd.

Wuxi Branch Offi ce

A-096 YangmingHi-Tech Industrial ParkWuxi Jiangsu 214024, ChinaPhone +86-10-852610-40Fax [email protected]


(Shanghai) Co. Ltd.

Chongqing Branch Offi ce

Room 17-03 AMetropolitan Tower 68Zou Rong Lu, Central DistrictChongqing 400010, ChinaPhone +86-23-63 70-36 00Fax +86 23 637 4-10 [email protected]


(Shanghai) Co. Ltd.

Guangzhou Branch Offi ce

Room 2003, 20/FCenter Plaza Tower B161 Linhexi Rd.Tianhe District GuangzhouGuangdong Province 510620, ChinaPhone +86-20-38 62-12 41Fax +86-20-38 62-12 [email protected]

United Grinding

Technologies Inc.

510 Earl Blvd.MiamisburgOH 45342, USAPhone +1-937-859-1975Fax [email protected]

United Grinding

Technologies Inc.

5160 Lad Land DriveFredericksburgVA 22407, USAPhone +1-540-898-3700Fax [email protected]

Körber Schleifring GmbH

India Branch Offi ce

99 Spencer Road, 1st FloorFrazer TownBangalore 560 005, IndiaPhone +91-80-41554-601/602Fax [email protected]

Mägerle AG Maschinenfabrik

Allmendstrasse 508320 Fehraltorf, SwitzerlandPhone +41-433-5566-00Fax [email protected]

Blohm Jung GmbH

Kurt-A.-Körber-Chaussee 63–7121033 Hamburg, GermanyPhone +49-40-7250-02Fax [email protected]

Blohm Jung GmbH

Jahnstraße 80–8273037 Göppingen, GermanyPhone +49-716-1612-0Fax [email protected]

Fritz Studer AG

3602 Thun,SwitzerlandPhone +41-33-43911-11Fax [email protected]

Schaudt Mikrosa GmbH

Saarländer Straße 2504179 Leipzig, GermanyPhone +49-341-4971-0Fax [email protected]

StuderTEC K.K.

Matsumoto Bldg. 2F4-10-8, Omorikita Ota-ku,Tokyo 143-0016 JapanPhone +81-36-80161-40Fax [email protected]

Walter Maschinenbau GmbH

Jopestraße 572072 Tübingen, GermanyPhone +49-7071-9393-0Fax [email protected]

Walter Machines

Asia Pacifi c Pte. Ltd.

25 International Business Park#01-53/56 German Centre,609916 SingaporePhone +65-65-6281-01Fax [email protected]

Ewag AG

Industriestrasse 44554 Etziken, SwitzerlandPhone +41-32-6133-1-31Fax [email protected]

Walter Machines UK Ltd.

B 13 Holly Farm Business Park,Honiley, Kenilworth, Warwickshire,CV8 1NP, Great BritainPhone +44-19-26-4850-47Fax [email protected]

Walter Kurim s.r.o.

Blanenská 128966434 Kurim, Czech RepublicPhone +420-541-4266-11Fax [email protected]

Walter Machines Italia Srl

Via G. Garibaldi, 4222070 Bregnano (CO)ItalyPhone +39-031-7708-98Fax [email protected]

Walter Japan K.K.

1st fl oor MA Park BuildingMikawaanjo-cho 1-10-14Anjo City 446-0056 JapanPhone +81-556-71-1666Fax [email protected]

Walter Máquinas Ltda.

Avenida XV de Agosto, 5.060Sorocaba, BrazilCEP: 18 085 290Phone +55-15-3228-6910Fax [email protected]

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motion_2011-1_en

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