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UNITED GRINDING Presents A World Premiere At EMO 2021

UNITED GRINDING Presents a World Premiere at EMO 2021

The UNITED GRINDING Group, a manufacturer of precision machines for grinding, eroding, lasering, measuring, and combination machining, is presenting a revolutionary innovation at EMO 2021 in Milan: UNITED GRINDING C.O.R.E. Each of the Group’s brands – MÄGERLE, BLOHM, JUNG, STUDER, SCHAUDT, MIKROSA, WALTER, EWAG and IRPD – will be on hand to see the innovation presented to the public on the first day of the trade fair (October 4, 2021 at noon local time).

No details about C.O.R.E. are being divulged ahead of the official market launch. Stephan Nell, CEO of the UNITED GRINDING Group, is only willing to reveal this much: “We have invested unwaveringly in research and development both before and during the coronavirus pandemic, to secure the future – not just for us, but above all for our customers. And when we talk about the future, it is inseparably linked to digitalization today and with an increasing work simplification in production.” In this connection, C.O.R.E. is intended to put the focus back on people – and in a truly revolutionary way. The brand name says it all: C.O.R.E. – Customer Oriented REvolution.

Experts from each of the Group’s three technology areas – surface and profile grinding, cylindrical grinding, and tool machining – worked within a joint team on this groundbreaking development. “This project reflects our bundled development expertise,” explains Christoph Plüss, CTO of the UNITED GRINDING Group. “Through C.O.R.E., we are laying the foundations for a new generation of machine tools to pave the way into the digital age.” The result is a world-first that encompasses all of the Group’s brands and machine types.

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Milling Instead Of Grinding With The Hand Angle Miller

Milling Instead Of Grinding With The Hand Angle Miller

The wide range of milling discs, special techniques when milling by hand, as well as the use with hand angle millers and in (partially) automated processes. The milling discs are available in the three different kinds “milling disc”, “double sided milling disc” and “doubleworker”, which aim different areas of application.

For all of those the following applies:

The surfaces processed with the discs are metallic bright, and therefore prevent cavities while welding. While working, the discs produce neither (unhealthy) dust nor heat, and thus no structural changes that come with heat. The amount of material removed and the fineness of the result depend on the toothing. The fewer teeth, the coarser the chips and the greater the amount of material removed. The more teeth a disc has, the finer the chips and the smoother the surface, but less material is removed. The specific toothing depends on the material to be machined and the disc size.

The discs can be used for the following tasks:

  • The milling disc gets used for bevelling, deburr and flatten as well as working out weld roots.
  • The double sided milling disc (DMD) is used to open weld roots, according to the literal translation of the German original description, that would be “weld root opener”. Due to the teeth geometry, it is not made for the tasks performed by a single sided milling disc.
  • The Doubleworker (DW) combines the scope of single and double sided milling discs, without the need to frequently change the tools. The teeth geometry of the double sided milling disc had been adjusted to resolve the problem of chips getting stuck in the chip chamber.

Maija-Frästechnik GmbH, founded in 2012, develops, produces and sells high-quality milling tools made of hard metal. The company owns the patent for milling discs, which was registered in 2000 by the later company founder.


Laser Process Measuring Technology For Precision Machining

Laser Process Measuring Technology for Precision Machining

Integrating laser measuring technology expands the possible applications of process measuring technology in grinding machines, supporting the user in his efforts to increase efficiency in precision machining. Article by STUDER.

Finishing processes on grinding machines often demand exacting tolerances in relation to dimension, form and position accuracies, as well as highly accurate surface qualities. Often, companies have empirical values available to fulfil these requirements.

However, with small lot sizes in particular, process evaluation on the machine is desirable, as intermediate measurement on external measuring machines and the resulting corrections prolong the processing time for part machining. These control measures would significantly increase process reliability and productivity. Solutions that can be flexibly used for a wide variety of workpieces are ideal and preferable.

Measuring Technology in Grinding Processes

Production engineers have diverse measuring functions available for process evaluation, which are based on different principles of production measuring technology. The measurement of process forces such as grinding forces (Ft, Fn) or comparative grinding spindle currents, for example, provide an index for achieving the service life of tools or, equally important, they enable the determination of fluctuating allowances, which can influence process stability and compliance with required tolerances.

In addition, tool costs can be reduced, as excessive dressing is prevented. Familiar acoustic touch sensors assist so-called contact detection in the grinding process to reduce grinding time, or monitor the true-to-profile dressing process with its envelope curve functions. Tactile measuring systems such as measurement and control systems for diameters or workpiece lengths, pneumatic systems or microsensors for longitudinal expansions of spindle systems also support increased process reliability.

Other measuring functions can also be described here, such as the use of camera or laser systems for process monitoring. Laser measuring technology in particular opens up interesting fields of application.

Integrating Laser Measuring Technology into Grinding Machines

STUDER can draw on more than 10 years of experience in the use of machine-integrated laser measuring technology, which have been evaluated for trials in the measurement of grinding wheels or workpieces. Such fundamental studies have a tradition at STUDER, to ensure the company is prepared for future trends in production technology. This knowledge and experience has been used to respond to the current requirements. The systems used in other industries for tool monitoring have been further developed by STUDER, on the basis of the latest laser measuring technology, only recently available, for measuring workpieces on grinding machines.

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A Remedy To Uncertain Times

A Remedy To Uncertain Times

Medical manufacturing company Straits Orthopaedic delivers on diverse medical applications with their flexible ANCA CNC grinding machines. Article by Duncan Thompson, ANCA.

If manufacturers have learned anything over the recent months, it is that you can take nothing for granted. Circumstances can change quickly and how you are set up to respond can be the difference between your business flourishing or folding. Recognising this, Straits Orthopaedic has been investing in ANCA machines as part of their strategy to be a flexible manufacturer in the medical tooling and component market. 

The events of COVID-19 this year are perhaps the most extreme example of rapid market change and resulting uncertainty. But, even after more normal circumstances return, manufacturers need to be constantly vigilant, watching and responding to changes in the market that provide new opportunities or necessitate a pivot in their business. 

ANCA CNC grinding machines have long been recognised in the industry for their flexibility. It is this kind of flexibility that allows ANCA users to produce parts for diverse applications, so they are not limited to just one customer or one application. Powerful software allows users to create programs for a broad range of cutting tools and components. While modular machine design means features can be easily configured to suit the varying needs of different applications. 

The medical industry offers exceptional and diverse opportunities for manufacturers, with ANCA grinding machines supporting international markets in the production of complex bone rasps, long rotary reamers and tiny dental drills and burrs, just to name a few. 

Straits Orthopaedics, based out of Malaysia, is a case-in-point of a company taking advantage of ANCA’s diverse capabilities. Already well established for contract manufacture of medical components, Straits Orthopaedics’ first tool grinder was an ANCA FX5.

Senior Process Development Engineer Vidyadhiraj Vidyadharan comments, “Custom made tools have become a significant part of our growth in the medical tool market. We need the ability to make special tools to varying customer requirements and to be able to do it quickly. ANCA’s FX5 with its flexible tool programming software has certainly allowed us to meet this need. Demand for our diverse range of medical drills, reamers and planers easily justified our second FX5.”

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New Holroyd Gear Grinding Centre Offers Greater Levels Of Efficiency In Precision Gear

New Holroyd Gear Grinding Centre Offers Greater Levels Of Efficiency In Precision Gear

A brand-new gear grinding centre from Holroyd Precision promises to bring higher levels of intelligence and efficiency to the production of specialised gears and tooth forms. Called the GT350, this latest machine from the Precision Technologies Group (PTG) company has been developed for one-off and batch grinding of precision spur and helical gears, worms and screws of up to 350 mm in diameter. It can also be used to precision grind compressor rotors.

Replacing Holroyd’s GTG2 model, the GT350 achieves accuracies in the order of DIN 2 and features the high power required for deep grinding operations. A specially developed extended machine bed allows screws and worm shafts of up to one metre in length to be accommodated. Dedicated software compensates for helical twist, and full topological capability comes as standard.

It is the GT350’s data collection and transfer capability, however, that could be of greatest interest to users. IO-Link communication technology, for example, is available with all new GT350 machines. “We selected IO-Link for its data-handling capabilities and its ability to communicate at every level of the production process,” says Holroyd Regional Sales Director, Steven Benn.

Simplifying the most complex processes

Maintaining the Holroyd tradition of building machines that simplify even highly complex manufacturing processes, the GT350 combines extreme rigidity with high power for both CBN and conventional deep grinding operations. Setup is rapid for optimised productivity and customers have the choice of either Siemens’ 840D controller or Holroyd’s in-house CNC and HMI system. On-board features include: automatic coordinate adjustment, in-cycle wheel dressing, integrated profile management and coordinate measurement. Grinding cycles are included for: spur gears; helical gears; crowned helical and spur gears with root or tip relief; worm gears of the form ZK, ZI, ZN and ZA; dual lead (duplex) worm gears; splines.

The GT350 also features Holroyd’s Profile Management System (HPMS) for highly accurate profile grinding, while an advanced touch-screen interface allows the operator to enter design drawing coordinates directly into the machine. Additionally, all gear, worm and spline profiles can be verified using the integrated Renishaw probing system, enabling automatic on-machine corrections to be made if necessary.

Compensating for helical twist

Holroyd’s design engineers have ensured that the GT350 automatically corrects the problem of helical twist – a condition that occurs when helical gears are ‘lead crowned’ to improve meshing and to reduce noise and wear. This is achieved through the use of specially written, dedicated software that both calculates and controls additional motions of the grinding wheel during the grinding operation.


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ANCA Launches CIM3D V9 With Time-Saving And User-Friendly Enhancements

ANCA Launches CIM3D V9 With Time-Saving And User-Friendly Enhancements

ANCA’s new CIM3D V9 release of the industry-leading CIMulator3D software has an upgraded interface with fresh colours and icons and is even easier to use with intuitive functionality. The latest technology and software design has been packed into this release offering time-saving benefits and interactive visualisation across the entire grinding process.

Thomson Mathew, ANCA Software Product Manager says: “This upgrade responds directly to what our customers want and need for effective tool simulation. CIM3D V9 allows for customisation based on regularly-used features no matter which industry. The simulation quality of ANCA’s software is unmatched and you can simulate complete grinding sequences.”

“The offline capabilities of using the latest CIM3D version mean important background calculations are easily verified, increasing machine productivity. This not only maximises machine time but for those working from home, CIM3D can be run independently on any computer – so it is possible to do all the programming remotely.”

“We have automated many manual steps and introduced process verification and analysis in a central hub to get improved cycle time, and better wheel and tool life. Collisions can be detected automatically and overall CIM3D V9 is more enjoyable and easier to use.”

The new software offers clearer visualisation with the customisable timeline panel – effectively a central dashboard for quicker and easier tool analysis. New tool programs can be verified for size, shape, machine clearance, cycle time estimates, and more.

ANCA’s software experts are in-house ensuring the features of CIM3D are responsive, user-friendly and tailored to the cutting tool industry.

Feature include:

  • Updated look and feel
  • Progressive material removal
  • Clear visualisation with the timeline panel
  • Tool balance analysis
  • Save time with background calculations
  • Visualisation of material removal rate
  • Improved measurement capabilities
  • Changes to the sectioning plane dialogue


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WALTER EWAG’s Michael Schmid On Thailand, Trends, And Future Of Grinding Industry

WALTER EWAG’s Michael Schmid on Thailand, Trends, and Future of Grinding Industry

Michael Schmid of WALTER EWAG discusses the Thailand market, opportunities and challenges, and trends shaping the metalworking industry in the region. Article by Stephen Las Marias.

Michael Schmid

WALTER EWAG Asia Pacific Pte Ltd, part of the United Grinding Group headquartered in Bern, Switzerland, specialises in tool grinding, laser machining, eroding, measurement, and software. Its machines are used in fields such as the watch industry, the dental, electrical, automotive and aviation industries, as well as in the manufacture of precision micro-components.

READ: Reducing Cost-Per-Part of Your Tools

WALTER EWAG is a system and solutions provider for complete tool machining. It offers an extensive product range  for manufacturing  and re-grinding  of rotation symmetrical  tools and inserts made of tungsten carbide, HSS , PCD PCBN   or any other super hard materials  like MCD , CWD and even natural diamonds.

At the recent METALEX 2019 event in Thailand, Asia Pacific Metalworking Equipment News sat down with Michael Schmid, managing director of WALTER EWAG in Singapore, to discuss the Thailand market, opportunities and challenges, and trends shaping the metalworking industry in the region.


Michael Schmid (MS): We have been doing business in Thailand for more than 20 years now. In fact, we installed our first CNC machines here in Thailand in 1996.

Currently, we have a training and demo centre in the country, where we do test cuts and demonstrations for customers. Our customer care, service engineers, and applications specialists, are all based here.

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MS: With our substantial product portfolio and the specialised team of technicians, we can actually cater to all needs in terms of tool making and resharpening required in the industrial environment—which Thailand has, such as the automotive, aerospace, semiconductor, and all kinds of metalworking industry.


MS: Some of the challenges are finding skilled people and developing know-how in cutting tool technology. But also, major challenges include productivity and quality, and being innovative in tool design.

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MS: Our aim is to help customers, educate them, and train them, through our software and machine design. There are a lot of possibilities to be creative. We help them become more creative in utilising our machines.


MS: If you look, for example, at our Helitronic Series, these machines are extremely  powerful and  have  very unique and efficient kinematics, which provides an ultimate stability and accuracy. All  that, together with our in-house developed Tool Studio software, open all kind of possibilities in terms of flexibility, dynamics and performance for our customers in today’s modern tool manufacturing  world.

READ: A Look at Walter’s Two-in-One Machining Concept

Last but not least our  tool grinding know how of over 50 years  has of course  influenced our todays  products in  unique way  as well.


MS: One of the big topics is Industry 4.0.  In this show, VDW is having a presentation about umati, a standardised interface linking machines. Besides that, of course, automation is always an issue. Lights-out production, smart manufacturing—these are something we hear every day from our customers, and a lot of companies are now working towards this. Apart from that, there are also new, innovative tool geometries, machines, tools, software—there’s a lot of possibility to change.

Of course, there are also new materials coming—lighter materials for e-mobility, for example. There industry is changing a lot—and I think that’s the interesting part in our business.


MS: I don’t want to be pessimistic, but I also can’t be too optimistic, because when I talk to people here at the show, and the customers throughout the year, we saw some declines here and there. But some industries are still doing well.

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It will be an interesting time to come in the next six to 12 months, because of all the changes happening. Maybe, we’ll have more time to think about new things for the industry. Considering this, I would not say it will be bad; I would say let us be all optimistic and look forward to a promising, interesting time.

Like I said, in the last years, we’ve been very busy. Maybe, now we have a little bit of time to think about how to do things differently, how to increase our efficiency; I think it should be a target for everybody because, if there is a crisis coming, and we get out of it, we should be fresh, more efficient, and more powerful.


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NUM Launches Form Compensation Option For NUMROTO Tool Grinding Software

NUM Launches Form Compensation Option For NUMROTO Tool Grinding Software

NUM has launched a powerful form compensation option for its renowned NUMROTO tool grinding software. The new option enables tool manufacturers to ‘close the loop’ between CNC tool grinding and measurement, in order to further increase process accuracy and consistency. The system inherently compensates for process variables such as temperature fluctuations and grinding wheel wear, and is likely to prove especially popular with manufacturers of the latest specialist precision tools, which demand unprecedentedly tight production standards.

READ: NUM Flexium+ CNC Enables Sheet Metal Laser Cutting System To Achieve Exceptional Accuracy

Operators seeking to maximise the accuracy of tools produced on CNC grinding machines generally use a coordinate measuring machine (CMM) to obtain probed measurements of the machined part, using this information to influence the production process during subsequent machining operations. Until now, NUMROTO users processed the results from the CMM with proprietary third party compensation software running on an external computer, before feeding a suitably corrected target profile back into the CNC machine.

READ: NUM Launches Active Vibration Control System For CNC Machine Tools

Developed in conjunction with several key NUMROTO end users, NUM’s new form compensation facility forms a fully integrated part of the company’s form cutter package and completely dispenses with the need for any third-party software. The data exchange between the CMM and the CNC machine can be handled by XML interface or by export/import of the DXF file via a local area network.

The form compensation software employs advanced filtering algorithms to create a very smooth and precise compensation profile. The software always calculates the orientation of the grinding wheel and the path speed from the original profile, so that only the position of the contact point on the cutting edge is compensated – and not the orientation of the grinding wheel. This ensures that the surface quality of the tool is unaffected by the compensation.


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