motion_2010-2_en

Processes in the spotlight How the SCHLEIFRING Group makes the most of resources and creates value for customers

MOTIONTHE CUSTOMER MAGAZINE OF THE SCHLEIFRING GROUP

VISIT: A day at the WALTER factory in Kurim

WELL POSITIONED: The new management of the SCHLEIFRING Group

COUNTRY SPECIAL: The SCHLEIFRING Group in Japan

I S S U E 2 / 2 0 1 0

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L_S.01_Titel_E.indd 1 23.09.2010 15:40:47 Uhr

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]

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L_S.02-03_Editorial_E.indd 2 23.09.2010 15:41:08 Uhr

E D I T O R I A L

3MOTION 02/10

Fully cost-effective

Dear Readers,

Yours sincerely,

Stephan Nell

Member of the SCHLEIFRING

management board

Cost-effectiveness and time savings in production

are vital for success in today’s global market. The

important thing is to view the value chain in its

entirety. Optimization programs often fail to in-

clude all the steps in the production process and

ignore certain aspects, which inevitably leads to

unsatisfactory solutions.

The SCHLEIFRING Group sees itself as your part-

ner when it comes to increasing your competi-

tiveness and adding value to your products and

services. We can support you – we are experts in

calculating the cost-effectiveness of production

processes, and our technologies provide effi cient

solutions for the whole process, enabling you to

fulfi ll orders faster, lower costs and attain excellent

quality standards.

The quality of our products and the reliability of

our processes are backed by our production know-

how, which we demonstrate in this issue of

MOTION using the example of our plants in Thun

and Kurim. For us, quality management does not

end at the gates of our workshops – it begins at

the purchasing stage and continues into our after-

sales service. Highly trained service technicians

are on call all over the world to give you support

quickly when needed. Thanks to programs like

SERVICE ACADEMY, our international network

works to a high standard that we are improving

all the time.

As the largest provider of solutions for hard fi ne

machining, we are constantly investing in the fu-

ture. Regardless of economic fl uctuations, we

work intensively in research and development and

focus on your needs so that we can continue to

provide you with optimum support in the future.

I hope you enjoy reading this issue of MOTION.

L_S.02-03_Editorial_E.indd 3 23.09.2010 15:41:08 Uhr

CONTENTS

4 MOTION 02/10

L_S.04-05_Inhalt_E.indd 4 23.09.2010 15:42:04 Uhr

5

C O N T E N T S

MOTION 02/10

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: Marc-Oliver Prier (dir.), Lutz Günther, Oliver Haastert, Kerstin Hebeler, Ira Schroers Layout: Steffi Pfl ugbeil

(dir.), Andreas Bahnsen Graphic editors: Julia Poppe (dir.), Nina Weinhardt Proofreading, editing and translation: SKH SprachKontor Hamburg GmbH Photos: A1 Pix (1), action press (1), Agentur

Focus/Jan Oelker (1), Alexander Kovar (11), Bildagentur Huber (1), Corbis (2), dpa (1), eyevine (1), F1 Online (2), iStockphoto (3), Ullstein Bild (2), VISUM (1) Lithography: Fire Dept. GmbH, Hamburg

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

N E W S

06 Latest news

COV E R S TO RY

08 Making the most of resources

The total cost of a machine is often

underestimated. The SCHLEIFRING

Group is able to accurately analyze

the effi ciency of grinding machines

with the help of a sophisticated calcu-

lation model

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

20 Committed to WALTER

Bauer Präzisionswerkzeuge has col-

laborated with WALTER for 30 years

26 Highly accurate

Weidmüller Interface uses BLOHM

machines to manufacture tools

28 Internal grinding

The combined forces of technology

and sales

32 Tongji University Shanghai

The SCHLEIFRING Group is operating

a grinding laboratory in cooperation

with the university

37 Increased productivity

New software from BLOHM JUNG

38 Grinding large workpieces

MÄGERLE machines are used by

Chinese customers

40 Report

A visit to WALTER in Kurim

43 News to use

Practical tips for your processes

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

16 Change of leadership

The strategic reorganization of the

SCHLEIFRING Group

22 Country special Japan

The Asian country is one of the most

important markets for grinding ma-

chines. The SCHLEIFRING Group has

long had a presence there

M OT I O N S & M O R E

14 A production process in pictures

How a machine is created

25 ReMOTION

GrindTec 2010, lectures by

S CHLEIFRING experts

30 A wet hobby

UGT employee Pat Corrigan is a

passionate diver

34 SERVICE ACADEMY

The STUDER program ensures global

quality of service

36 Promotion of young talent

Students and school pupils at

BLOHM JUNG

16

L_S.04-05_Inhalt_E.indd 5 23.09.2010 15:42:08 Uhr

N E W S

Despite strong fl uctuations in the economy, SCHAUDT

MIKROSA was able to increase sales of its CamGrind S

and CamGrind L cylindrical grinding machines in China by

over 50 per cent over the past 18 months. ‘There are two

good reasons for our success in the People’s Republic,’ says

Michael Uhl, Regional Sales Manager for Asia at SCHAUDT

MIKROSA. ‘There has been a continued strong rise in the

demand for machine tools and we were able to deal with

our customers’ enquiries quickly and fl exibly thanks to our

SCHAUDT MIKROSA

Successful double act

Best seller: The

CamGrind L is in

demand in China

6 MOTION 02/10

The STUDER S22 production platform can machine work-

pieces using many different techniques, such as con-

ventional cylindrical grinding, form and thread grinding,

heavy-duty applications with wide grinding wheels or high

speed grinding (HSG). STUDER has now developed an in-

tegrated handling system, called ecoLoad, for the S22. It

can be used for workpieces of up to 50 mm in diameter and

250 mm in length. High quality and effi ciency, compact de-

sign and easy handling make this system particularly ap-

pealing. Programming tools, for example, which are inte-

grated into the grinding machine control system, guarantee

fast and user-friendly access to individual programs. Work-

piece positions are recorded with the help of the teach-in

technique, resulting in short changeover times. STUDER

ecoLoad is also suitable for all cooling lubricants. It is a

system with a clearly defi ned interface between the inte-

STUDER

New handling system

Easy to use, high quality: Thanks to ecoLoad, the STUDER S22 can machine wide

workpieces using various technologies

grated handling system (slide and carriage) and the work-

piece peripherals. This allows customers to add their own

peripheral devices.

CamGrind S: 50 per cent sales

growth in the People’s Republic

enlarged sales team.’ Machines made by SCHAUDT can be

found on the shop fl oors of well-known companies who use

them to manufacture printing rollers, railway axles, drive

shafts for wind power stations, camshafts and parts for the

aerospace industry, among others. One of SCHAUDT

MIKROSA’s biggest customers on the Chinese market is a

camshaft manufacturer. After purchasing fi ve CamGrind L

with SpeedLoad (see also page 43) in 2009, this company

has now ordered a further ten machines of the same type.

Over the next two to three years they will be called up for

delivery to different [email protected]

[email protected]

L_S.06-07_News_neu_E.indd 6 23.09.2010 15:42:21 Uhr

7

EWAG L ASER L INE

Technology for tomorrow

RETROFIT TING

Well equipped for new tasks

should provide. Whether this is strictly

feasible and which parts and what type

of work is needed to achieve this, will

only be determined by our design de-

partment with the help of an engineering

assessment. We will then supply the

customer with all the necessary infor-

mation and retrofi t the machines accord-

ingly,’ says Gerhard Mühlemann, Parts

Service Manager for STUDER Service.

‘After the retrofi t has been completed,

the machine is ready to be used for its

new production tasks.’ Advantage will

often be taken of a retrofi t or modifi ca-

tion to carry out a complete or partial

overhaul (see page 35), after which the

machines are as good as [email protected]

EWAG has succeeded in taking

a technological quantum leap

by developing laser machining for

workpieces made of superhard ma-

terials. The three-dimensional ma-

chining of these materials in one

clamping opens up entirely new

dimensions. For the fi rst time ever,

it is possible to machine the cut-

ting edge and chip breaker at the

same time on the same machine

with a high quality fi nish. The gain

in terms of quality, precision and

productivity has now reached a

new, unprecedented level. LASER

LINE, the latest development from

EWAG, was presented for the fi rst

time at the demo days in June in

front of 120 guests.

thomas.fi [email protected]

The requirements for grinding machines often change faster than expected.

For instance, if a customer expands his range of parts, the range of functions

increases or a machine needs upgrading. In such cases, retrofi tting can be helpful.

STUDER offers customer-specifi c solutions for this purpose. Qualifi ed service

technicians (see

page 34) fi rst deter-

mine whether the

machine needs to

be collected and

taken to the STUDER

factory or if the re-

furbishment can be

carried out at the

customer’s site.

‘The service techni-

cian can identify on-

site which new func-

tions the machine

LASER LINE:

Presentation

at the EWAG

demo days

MOTION 02/10

Example of retrofi tting: The drawing shows a change to the wheelhead

confi guration during a complete overhaul at the factory where it was made

Quantum leap:

The new

LASER LINE

from EWAG

L_S.06-07_News_neu_E.indd 7 23.09.2010 15:42:24 Uhr

C OV E R S T O RY

EFFICIENT USE OF RESOURCES

Everything under controlAnything that does not add value should be avoided. When deciding on the purchase of a new machine tool, it may be worth looking beyond the process at the bigger picture.

Down to the last detail:

Many features

increase the

profi tability of

grinding machines

8 MOTION 02/10

L_S.08-13_Titelgeschichte_E.indd 8 23.09.2010 16:49:01 Uhr

More fl exibility and versatility – these

are the demands the market makes

on manufacturing companies. Perfor-

mance, cost and output can only be im-

proved if a systematic approach is fol-

lowed. When it comes to the acquisition

of new production equipment, buzz

words like just-in-time production, lean

manufacturing, value stream mapping

and others run easily off the tongue. But

there is more to choosing the right ma-

chine tool. Even performing a cost ana-

lysis that answers questions relating to

maintenance and service, reliability and

precision and the consumption of energy,

coolant and tools is not suffi cient. Ulti-

mately production costs and the payback

period of a machine tool are largely de-

pendent on other determining factors.

These include:

Shorter process chains and process

times

Optimized machining times

Reduced retooling times, setup times and idle times

Reduced error rates

Reduced transport costs

Space-saving production

Lower labor costs

Fewer interfaces

Lower administrative costs

Processes in the spotlight

The key is therefore to avoid using re-

sources that do not create value. In

order to analyze processes, STUDER

has developed a model to determine

the cost-effectiveness of machine tools

that takes all relevant factors into ac-

count (see diagram on page 10). It al-

lows users to quickly calculate the pay-

back period of a new acquisition and

base their investment decision on sol-

id facts: ‘When it comes to purchasing

a new grinding machine, more often

than not the user will only compare the

purchase price, cycle times and grind-

ing quality of the old machine with

those of the new machine,’ explains

Antonio Bottazzo, Sales Manager at

STUDER. ‘Usually the grinding process

is only one of a number of machining

steps.’ For this reason, the Swiss grind-

ing experts and the customer look at

the whole process together and try to

fi nd the best possible solution from this

perspective. Expensive multifunction-

al machines, even if they seem over-

qualifi ed at fi rst, are often the better

alternative in the long run. They tighten

process chains and can also be univer-

Optimal solution:

Analyzing grinding

processes to get the

best results for

your customers

Monitoring processes: Multifunctional machines are the best alternative in the long run

9MOTION 02/10


sally adapted to new manufacturing

requirements. Complex workpieces are

usually machined in several steps on

many different machines. This appears

to be economical, as the machines are

usually older and thus written off. What many companies fail to consider when

examining their costs is the fact that each machine requires space, uses energy

and has to be serviced. Each re-clamping, adjustment and temporary storage of

a workpiece is not just a potential source of errors but also loses time during

which no value is created. On the other hand, administrative and personnel costs

Keeping a grip on grinding processes: Optimum results can be achieved if process costs are kept under control

Cycle time and investment are just two of many parameters that determine the cost of a workpiece.

WORKPIECE COSTS: MANY FACTORS INFLUENCE EFFICIENCY

Investment/residual value

Tim

eM

atu

rity

le

vel

Capital costs

Write-offs

Machine setter cost

Reject costs

Cycle time

Piece rate

Cost ofpremises

Service life ofproduction system

System availability costs

Working materials Energy/Air/Cooling lubricant

Cost of personnel

Machine operator cost Allocation of timeper workpiece

Costper

workpieceEquipment setup time

Tooling costper workpiece

Lifetime

Cost of premisesSpace required

Maintenance

Overall equipment effectiveness. Man hours

Labor costs

Working material requirements

Workload

Lot size

Workpieces

PersonnelWorking materials

Change of design

Rejects

Setup time

Change of design

Downtime

Quantity per cycle

Tooling costs

Reject rates

Inp

ut

Preparation of themanufacturing system

Production time

C OV E R S T O RY

10 MOTION 02/10


EFFICIENT MANUFACTURE OF MOLD CORES

The example shows how the cycle time of approx. eight days can be slashed to a net

processing time of just 14 minutes.

C1

T1

2 mins.

2 mins.

2 mins.

3 mins.

2 day

2.5 days

1 day

1 day

1.5 days

Processing time

Machining time approx. 14 minutes

Idle time approx. 8 days

Mac

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Co

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:sp

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Machining time

Setup time

Idle time

are high. However, a closer look reveals

that net process time is minimal com-

pared to cycle time (see example of

mold core). When considering a new

acquisition, one should not just look at

one specifi c machine or one specifi c

grinding process that needs replacing,

but at all previous and any subsequent

processing steps of a workpiece, this

could then be the fi rst step towards the

effi ciency of the whole process chain.

SCHLEIFRING customers can now use

the special profi tability calculation tool

to compare the costs of their current

machining process with those of com-

plete machining. Based on the assump-

tion that the machines are a one-off

investment, the program compares

their costs and benefi ts. Cost savings

are evaluated by comparing the process-

ing costs of the workpiece.

Individual processing of

mold cores

If we look at the example of mold

cores, processing these workpieces

usually takes place on six different

machines in six steps: taper grind-

ing, cylindrical grinding, hard

turning, milling grooves, erod-

ing cavities on the end face and

manual spot facing after hard

turning. This entails a great deal

of cost in terms of time, personnel

and logistics. Errors may creep in with

each new clamping and setup. Complete

machining of parts on one machine in a

single clamping is better, more accurate

and without the risk of errors. The ver-

satile STUDER S242 combination hard turning and grinding machine manufactures

complete mold cores. The new process thus eliminates unnecessary idle times,

minimizes transport costs and achieves an increase in production of up to 50 per

cent. ‘Needless to say, compared with conventional CNC cylindrical grinding

machines, the S242 is a more expensive machine,’ says Antonio Bottazzo, ‘but it

pays for itself faster than you would think because it substantially reduces the

cost per workpiece.’ Complete machining of the mold core reduced the cycle time

of eight days to a net processing time of around 14 minutes (see diagram above).

Unit costs were reduced by nearly half. The payback period for the machine is less

than 4 years and high quality products can be supplied to customers earlier. Am-

ortization can take care of any other non-productive incidental expenses and

A true all-rounder: The STUDER S242 completely

machines mold cores in a single clamping

Quick payback: The

S242 achieves

productivity increases

of up to 50 per cent

4 mins.

1 min.

11MOTION 02/10


C OV E R S T O RY

Most economic production solution: Combined machining on the BLOHM PROFIMAT MC 607 at PCI

in a single clamping. Equipped with an automatic tool changer for up to 24 grind-

ing wheels as well as drilling and milling tools, the versatile 5-axis CNC profi le

grinding machine always has the perfect tool for every machining operation.

Since complete machining came into use at PCI, long idle times, changeover

times and setup times have become a thing of the past. Production time for tur-

bine blades reduced by 75 per cent, while at the same time product quality sig-

nifi cantly improved.

Two in one

The desire to move into a new area of business is sometimes behind the decision

to buy a machine tool. The manufacture of milling cutters and drills made of

superhard materials is such an area. Here, it is not only essential to fi nd an effi -

cient machine to cope with the new technology but also to ensure a level of

fl exibility which also allows the machines to be utilized for conventional tasks.

Dual use: The

dielectric fl uid

serves as an insulator

and coolant

Flexible and effi cient:

The HELITRONIC

DIAMOND

improve the cost-effectiveness of the

S242 even more

Versatility inspires

confi dence

Flexibility to meet customer needs,

just-in-time production and high-spec-

ifi cation materials like Inconel create

new challenges for suppliers to the en-

ergy and aerospace industry on a daily

basis. Here too, combined machining

on one machine is the most economical

manufacturing solution. Precision

Components International (PCI), for

instance, a customer of BLOHM JUNG

based in the US, uses the BLOHM

PROFIMAT MC 607 in the production of

turbine blades for contour milling, drill-

ing, reaming, deburring and grinding

Production time

reduced: Parts for the

turbine industry

12 MOTION 02/10


When clamping becomes critical …Extraordinary applications demand extraordinary solutions. Many workpieces cannot be properly clamped by virtue of their unique characteristics. We develop targeted customized 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 μm range

The HELITRONIC POWER DIAMOND by WALTER is an ex-

ample for an ideal entry-level machine for machining PCD.

The 5-axis CNC machine with automatic electrode and grind-

ing wheel changer tackles eroding and grinding tasks in a

single tool changing operation. First of all, the hard metal

body of the tool is ground, before the sintered PCD bars or

inlets are then rough ground and fi ne ground as part of a

four-stage EDM process. This two-in-one concept eliminates

changeover times, idle times and setup times. If the work-

load for PCD tools is low on occasion, then the HELITRONIC

POWER DIAMOND doubles up as a fully-fl edged tool grind-

ing machine. The dielectric fl uid, which acts as an insulator

during the EDM process, serves as a coolant during the

grinding process.

Conclusion

The SCHLEIFRING Group has a lot to offer when it comes to

optimizing costing factors: long system life, guaranteed by

well-engineered and solid machine construction and fast

and professional service, low space requirement thanks to

compact machines, and short setup times with technical

support from StuderTech or virtual processing with WALTER

ToolStudio.

Last, but not least, SCHLEIFRING Group machines help users

to supply their customers with a better quality product more

quickly at a lower price and to achieve a successful market

position. ‘Anyone who decides in favor of one of our machines

chooses not only a pioneering technical solution but also a

highly cost-effective solution,’ says Antonio Bottazzo.

Well-engineered and solid:

The machine construction

of the SCHLEIFRING Group

has a lot to offer


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

14 MOTION 02/10

What makes a STUDER machine so sophisticated? A look into the assembly shop of this grinding machine manufacturer from Thun, Switzerland, provides the answer to this question.

AT A GL ANCE

A machine is created

Every STUDER machine is based on

a well thought-out concept. Follow-

ing investments in new infrastructure

and switching to space saving and

effi cient fl ow assembly, throughput

times have been hugely reduced in

recent years.

STUDER has all the important process

steps in the manufacture of a machine

under control. Every single one has been

developed in-house. Core components

such as the motor spindle, the workhead

and the tailstock are all manufactured

in-house. Even the machine base is made

in STUDER’s own GRANITAN® casting

foundry. The intuitive software is also

an in-house development. Various soft-

ware tools ensure user-friendly opera-

tion. Repeated quality checks guarantee

optimum functionality of the machines.

Prior to shipping, experts check and

record whether the product meets the

individual customer’s requirements.

Only then will another one of around 600

machines per year leave the factory to

start its journey to the customer.

1) Machine bases

Patented by STUDER and continuously

developed, the GRANITAN®machine

base forms the basis of all machines of

the Thun-based company

7) Software

The STUDER software

is installed. Tools such

as StuderGRIND,

StuderTechnology,

StuderProfi l and

StuderFormHSM ensure

optimum use of the machine

6) Final assembly

In the STUDER fi nal assembly hall,

employees assemble more than 600

new grinding machines per year.

Sophisticated logistics processes

guarantee short throughput times

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

p e t e r . d a e h l e r @ s t u d e r . c o m +++

FURTHER INFORMATION

L_S.14-15_Fotoreportage_E.indd 14 23.09.2010 15:43:56 Uhr

15MOTION 02/10

3) Surface grinding

Surface grinding of longitudinal

slides takes place on precision

surface grinding machines from

sister company MÄGERLE

4) Spindle assembly

One of STUDER’s core competencies

is the manufacture of motor spindles

9) Shipping

The machine is ready. Another customer can

look forward to the delivery of his new STUDER

5) Module assembly

The workhead, another STUDER

speciality, is assembled in the

module assembly workshop

2) Manufacturing

The casing of the workhead is

manufactured in the STUDER

production facility on interlinked

machining centers. The automatic

pallet system guarantees

high fl exibility

8) Test grinding

Each machine is thoroughly

checked before leaving the

STUDER factory

L_S.14-15_Fotoreportage_E.indd 15 23.09.2010 15:44:00 Uhr

16 MOTION 02/10


have its own management. This will ensure that customers are offered the best

possible solution from the whole range of Group services to meet their specifi c

needs. All brands within the divisions will be retained. For Richard Bauer, Chair-

man of the Management Board of Körber Schleifring GmbH, the advantages of

this reorganization are obvious: ‘We have clear lines of responsibility and short-

er chains of decision-making. We can thus effectively bring together the strengths

The core issue here is extensive re-

orientation in the form of three new

engineering divisions, bringing togeth-

er surface and profi le grinding under

the JUNG, MÄGERLE and BLOHM

brands, tool grinding under the WALTER

and EWAG brands and cylindrical grind-

ing under the STUDER, SCHAUDT and

MIKROSA brands. Each division will

THE SCHLEIFRING GROUP STRENGTHENS TECHNOLOGY DIVISIONS

Cooperation offers advantages

No other sector has been hit as hard by the global economic crisis as the machine tool indus-try. The SCHLEIFRING Group has used this diffi cult time to evaluate its strategies, structures, processes and products – always with the customer and his needs in mind. MOTION talked to the new SCHLEIFRING Group management about the strategic reorganization.

Good starting position:

Combining strengths, setting a

fast pace and achieving goals

L_S.16-19_Interview_E.indd 16 23.09.2010 15:44:21 Uhr

17MOTION 02/10

panies is vital,’ says Stephan Nell. The head of the cylindri-

cal grinding division has also assumed responsibility for

distribution and service on the SCHLEIFRING Management

Board. ‘We want to offer all customers of the SCHLEIFRING

Group companies the same high standard of service qual-

ity at the same time,’ explains Nell. That is why we have

set up a small team to deal with joint issues such as uniform

standards and innovative service offers.

New technologies for new markets

Innovation is on the agenda for the service side but even more so for the machines.

‘We have the distinct advantage that we in the KÖRBER Group can continue to

invest heavily in Research and Development, even in diffi cult economic times,’

says Dr Roland Rütti, who is responsible for the surface and profi le grinding divi-

sion as well as the related area of technology on the Management Board. ‘We

will strive to better coordinate the product portfolio of our companies within the

divisions,’ adds Rütti. As system suppliers, the SCHLEIFRING companies are able

to offer solutions tailored to the needs of their customers.

In this, they are able to build on a solid foundation. ‘We are always at the leading

edge of technology where grinding is concerned,’ says Rütti and refers to exten-

sive process know-how, long-term experience, reliability and top quality. He sees

potential mainly in the development of new technologies, for both traditional and

new markets.

of the globally positioned SCHLEIFRING

Group with the customer contact, mar-

ket knowledge and fl exibility of the divi-

sions.’ The new SCHLEIFRING Manage-

ment is already working at a brisk pace.

One of the fi rst decisions was to reinte-

grate the Service division, which was

previously outsourced to a dedicated

company, back into the individual com-

panies. The transfer is progressing

swiftly. ‘Customer responsiveness is as

important to the service sector as speed

and fl exibility. Being close to the com-

The new Executive Board of the SCHLEIFRING Group: Richard Bauer and

Gustel Baumert (standing, from left) Stephan Nell, Heinz Poklekowski and

Dr Roland Rütti (seated, from left)

Developing new markets: A view of the machine assembly shop at

KÖRBER SCHLEIFRING MACHINERY in Shanghai


18


MOTION 02/10

No concessions: Quality manufacture made by KÖRBER SCHLEIFRING Committed team: Great motivation and extensive know-how

‘Today, we are more than ever faced with the challenge of offering our customers

the best possible solutions at reasonable and fair prices. That is why we have to

keep a tight rein on our costs,’ says Heinz Poklekowski emphasizing the growing

importance of joint strategic purchasing within the Group. For Poklekowski, the

member of the SCHLEIFRING Board who is responsible for the tool grinding and

strategic purchasing division, the size of the globally-positioned SCHLEIFRING

Group gives a clear competitive edge. ‘We have achieved a lot in the past. But

through the sensible pooling of purchasing demands, it is possible to achieve

further synergies.’ Cooperation with the other divisions of the KÖRBER Group

offers further opportunities. One thing is clear, though: no concessions are made

with regard to quality.

Workforce a success factor

Within the context of realigning the SCHLEIFRING Group, the management team

has been able to rely on past strengths. These include the excellent brand image,

outstanding technologies and a worldwide

presence in sales and service. ‘We are

starting from an excellent position. We

have worked hard and done our home-

work,’ says SCHLEIFRING Chairman

Richard Bauer. In doing so, the new

SCHLEIFRING management can build on

its most important success factor – the work-

force. ‘We have a very committed team of employees

with a high level of motivation and extensive know-how.’ That is

why Bauer is sure that, with the markets recovering, the SCHLEIFRING Group

will continue to be the best partner for all grinding tasks.

Making use of synergy effects

Like the rest of the sector, the

SCHLEIFRING Group has a long way to

go. ‘The machine tool sector has always

been strongly dependent on economic

trends. And therefore we are used to the

constant ups and downs,’ says Gustel

Baumert, Managing Director of Körber

Schleifring GmbH. ‘However, the recent

slump far exceeds anything we have ex-

perienced in the past.’ After the initial

stabilization, the sector is now feeling a

marked improvement. But a perceptible

recovery will not be felt until the second

half of the year at the earliest.

Premium workpiece: Guaranteeing

the best solutions at fair prices


19MOTION 01/10

Meister AbrasivesInternationalwww.meister-abrasives.com

Make A Quality Decision


20 MOTION 02/10

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

High-strength superalloys:

Engine components

require special tools

TOOL GRINDING

Hand in hand

A joint success story: precision machine tool manufacturer Bauer and WALTER both profi t from their long and strategic partnership.

They have come a long way: from a

small regrinding company working

in a double garage to an internationally

acclaimed manufacturer of precision

milling tools for machining engine com-

ponents – this describes the develop-

ment of Bauer Präzisionswerkzeuge

GmbH of Pleystein, Germany. This suc-

cess was achieved through much hard

work, skill and the consistent use of tool

grinding machines and measurement

technology by WALTER. Meanwhile,

both companies can look back on a part-

nership that has lasted almost 30 years.

Following a chance meeting in 1981, a

strategic cooperation developed whereby all steps were carefully planned to-

gether. Today, Bauer specializes in the manufacture and maintenance of solid

carbide tools which are among the best available due to their precision, productiv-

ity and operating life. The family business, based in the Upper Palatinate region

of Germany, soon became one of WALTER’s pilot customers and supports the

company in the development of new machines and software programs.

Double decker and racing bike

A total of nine tool grinding machines and three measuring machines by WALTER

are used at Bauer: three HELITRONIC POWER, four HELITRONIC VISION, one

HELITRONIC MICRO and one HELITRONIC CLASSIC as well as one HELICHECK

BASIC, one HELICHECK PRO and one HELICHECK PLUS. Since early 2010, Bauer

L_S.20-21_WALTER_E.indd 20 30.09.2010 12:45:24 Uhr

21MOTION 02/10

has been using the HELITRONIC MICRO specifi cally for grinding very small preci-

sion milling cutters with diameters of less than 5 millimeters. The HELITRONIC

MICRO guarantees tolerances of two μm with absolute repeating accuracy. ‘We

could also machine these milling cutters on the HELITRONIC VISION machines.

But would you take a double decker bus to buy bread if a racing bike would do the

job?’ says Joachim Bauer. The HELITRONIC MICRO takes the pressure off his four

HELITRONIC VISION machines. These are mainly used for more complex tasks

and larger tools such as in-house designed Christmas tree milling cutters for

manufacturing blade grooves for turbine rotors and discs. Machining such tools

often takes several hours. Grinding is carried out using the facetted cam relief

method. ‘Thanks to linear direct drives, this method is 20 per cent faster than

conventional 5-axis machines with recirculating ball screws,’ explains Volker

Bauer, Area Sales Manager for South-East Germany at WALTER. Further advan-

tages: due to axial and radial cam relief form errors are prevented, the tool is more

robust and resharpening is easier. All grinding machines are housed in an air-

conditioned workshop. The controlled coolant condition keeps not only the grind-

ing wheel and the workpiece but also the drives at a constant temperature. In

addition, a special fi lter removes any particles larger than three μm from the cool-

ant and ensures high surface quality. Material or form errors caused by tempera-

ture zones or temperature fl uctuations are effectively eliminated, absolute preci-

sion is guaranteed.

Virtual tool development

From single part production to batch production and mass production – with its

range of machinery, Bauer is prepared for all eventualities and runs a highly -

effi cient production operation. All HELITRONIC VISION machines (three single

spindle machines, one twin spindle machine) have an automatic grinding wheel

changer with twelve station tool changer and cooled spindle. They are equipped

with easy-to-load lift loaders, which, depending on the shank diameter, can hold

up to 500 milling cutters. Up to three cassettes are available for tool holding – an

ideal choice for multi-shift operation with virtually no manpower, it guarantees

highest productivity especially when grinding highly complex geometries and

large batches. ‘We use WALTER’s HELITRONIC ToolStudio on all machines. Con-

sequently the user interface is the same everywhere and our employees quickly

fi nd their way round every machine,’ explains Joachim Bauer. The software also

gives the option to design new tools on the PC, submit them to the customer and

make any necessary changes virtually. Once the tool has been fi nalized, the vir-

tual grinding process can begin. Only when everything works perfectly in simula-

tion, is the fi rst real tool ground. The fi rst ma-

chined part is perfect. Test grinding – which is

associated with a high investment in personnel,

time and material – is no longer necessary.

For precision and process reliability: Machine

tempering and air-conditioning in the production hall

Profi table: High-precision milling cutters account for

70 per cent of Bauer’s turnover

Exact measuring: Bauer opts for WALTER machines

+ + + 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 . c o m + + +

FURTHER INFORMATION

‘We have never been disappointed by WALTER. The company really responds to their customers’ problems. Together we have always managed to find a solution’

Joachim Bauer, CEO of Bauer Präzisionswerkzeuge GmbH

L_S.20-21_WALTER_E.indd 21 30.09.2010 12:45:34 Uhr

22 MOTION 02/10


major three places in Japan where this event is celebrated. ‘Any visitors I take along

to the Tanabata Matsuri festival are always impressed by the great atmosphere.

Another recommended highlight for foreign visitors is Nagoya castle, not far from

Anjo,’ reports Nakamura. The 59-year-old engineer is in charge of WALTER Japan.

From Anjo, he keeps in close contact with the SCHLEIFRING head offi ce and the

companies in Germany and Switzerland.

Serving different industries

The SCHLEIFRING Group is an important supplier of machines for a variety of indus-

tries. ‘I see a general trend towards high-quality products. This means more fl exible

When asked to say something about

his adoptive city of Anjo, Yuji

Nakamura raves about the Tanabata Mat-

suri festival. According to legend, the

stars Vega and Altair once fell in love. But

they can only meet once a year. The fes-

tival celebrates this meeting. There are

COUNTRY SPECIAL

In the land of the rising sunJapan is one of the mostimportant machine toolmarkets. The SCHLEIFRING Group has two subsidiariesin the country.

Tourist attraction:

Nagoya castle was

originally built in 1532

JAPAN IN BRIEF

Population: 127 million (2008)

Capitol: Tokyo

Currency: Yen

GDP: 5,704.61 billion USD

(2009)

GDP per capita: 38,210 USD (2008,

nominal)

National language: Japanese

Area: 377,930 km²

National holiday: May 3: Constitution

Day

Tokyo

Anjo

L_S.22-25_Japan_E.indd 22 23.09.2010 15:45:09 Uhr

23MOTION 02/10

Japan is also a yardstick when it comes

to customer orientation and service de-

livery. ‘Customers over here expect a

lot from our experts,’ says Ko Miyata,

Sales Manager at StuderTEC. ‘We are

therefore extremely proud to be able to

satisfy these high expectations with our

small but highly competent team.’

Miyata also recognizes the benefi ts for

the global SCHLEIFRING network.

‘What we are learning here and have

already put to use will prove useful in

other markets.’ Founded in 1999 as a

service company, StuderTEC is cur-

rently setting up a new nationwide net-

work of distributors (see MOTION

1/2010), to ensure optimum coverage

of the Japanese market.

software, greater accuracies and more

productivity,’ says Nakamura. WALTER

serves customers from the automotive

segment, regrinding companies, manu-

facturers of cutting tools and the aero-

space industry. Machines of the EWAG

brand which are also distributed by

WALTER Japan are in especially high de-

mand by watchmakers such as Citizen

Watches and manufacturers of ballpoint

pens. Due to close links with STUDER’s

Japanese subsidiary StuderTEC which is

based in Tokyo, Nakamura is aware that

the company scores major points in this

segment, mainly with manufacturers of

jet engines and hydraulic equipment. In

Japan, STUDER machines are also cho-

sen by customers from the automotive

sector and the machine tool builders.

Sought-after accuracy

‘Japanese companies especially ap-

preciate the high accuracy and stabil-

ity of SCHLEIFRING machines,’ says

Nakamura. With WALTER Japan and

StuderTEC, the SCHLEIFRING Group

has two wholly-owned subsidiaries in

the land of the rising sun and is able to

offer a broad range of machinery, for

example at the JIMTOF – Japan Inter-

national Machine Tool Fair which takes

place from October 28 to November 2

in Tokyo.

Landmark: Mount Fuji is considered a mythical and

sacred mountain by the Japanese. It is reverently

referred to as Fuji-San

WALTER Japan: Yuji Nakamura (front row, fourth from left) and his staff look after distribution and service of

WALTER and EWAG machines. Based in Anjo, they support customers all over Japan

Production at Toyota: The Japanese company is one of

the largest car manufacturers in the world

Vibrant metropolis: Shinjuku is one of the hottest

nightlife destinations in Tokyo

Colorful festival: The Tanabata Matsuri festival is celebrated in the beginning of August

A much sought-after photo subject:

The 16-m-high red gate of Miyajima

was built in 1875



24 MOTION 02/10

Place of relaxation: Japanese

garden in the autumn

Always ready to help: The fi ve-strong team at StuderTEC. A new distribution network will

further increase market coverage

In spite of the current somewhat strained

situation prevailing on the Japanese ma-

chinery market, Nakamura is optimistic

that Japanese customers will soon in-

vest more and that the upward trend is

set to continue. WALTER and StuderTEC

have a total of 20 employees in Japan

who are working with passion and en-

thusiasm towards this goal. True to the

old Japanese saying: ‘Diligence is the

mother of good luck.’

BRIEF GUIDE TO BUSINESS ETIQUET TE

How things are done in Japan

Correct behavior is crucial to business

success. MOTION reveals some

things to remember when in Japan.

General information: Saving face is crucial

in Japanese society. You should therefore

never embarrass your opponent. In the

‘land of the rising sun’ a ‘yes’ does not

automatically mean agreement; it simply

demonstrates that they have been listen-

ing to you. The same applies to nodding.

Obligations like ‘One good turn deserves

another’ are par for the course in Japan.

Greeting: Bows are performed with the

back straight. Never initiate a handshake.

If it is offered, do not shake too fi rmly.

Business cards are always given and

received with both hands and in a way

that the card can be read. Examine your

business partner’s card immediately as

a show of respect.

Punctuality: In Japan meetings always

take place at the agreed time. If you are

going to be late, call and think of a good

excuse.

Karaoke: Karaoke bars are part of Japa-

nese business culture. Even if you can’t

sing you will score points on the karaoke

stage.

Eating and drinking: Never stab food

with your chopsticks. It is allowed to

slurp noodles in soup. It is customary to

always pour your neighbor a drink, nev-

er yourself.

Don’ts: Tips are considered an insult. A

direct ‘no’ during negotiations comes

across as being rude. It is better to use

another polite expression. Expansive

hand gestures and aggressive outbursts

will lead to loss of respect.

+ + + n a k a m u r a @ w a l t e r . c o . j p + + +

i n f o . j p @ w a l t e r - m a c h i n e s . c o m

+ + + k o . m i y a t a @ s t u d e r . c o m + + +

FURTHER INFORMATION

IMPORT OF MACHINE TOOLS INTO JAPAN IN 2009*

60.7 Turning/milling machines

10.1 Boring machines

30.0 Gear cutting machines

45.3 Grinding machines

32.8 Other

Total of machine tools: 372.9

* in million euros Source: Japan Machine Tool Importers’ Association, February 2010

118.2 Forming machines

22.7 Eroding machines

27.8 Laser processing machines

25.3 Machining centers


25MOTION 02/10

The SCHLEIFRING Group gets top marks

GrindTec is one of the top international trade fairs for

grinding technology. Even in turbulent market times, it

recorded more exhibition space in 2010 than in the boom

year of 2008. With 11,250 visitors, it set a record for at-

tendance. Despite the tense situation in the sector, the

SCHLEIFRING Group was able to maintain its sales fi gures

at the level of the previous GrindTec. Just as in the record

year of 2008, the Group sold 30 machines at the grinding

technology trade show. ‘GrindTec has clearly surpassed

our optimistic expectations,’ says Peter Lütjens. ‘From the

fi rst to the last day of the fair we had a tremendous rush

of visitors to our booth. We are pleased with the orders

and the many positive enquiries taken,’ says the marketing

manager of the SCHLEIFRING Group. The next GrindTec

takes place in March 2012.

Sought-after expertise

Experts from the SCHLEIFRING Group

are valued as speakers at technical sym-

posia. Dr Heinrich Mushardt, Head

of Strategic Development at KÖRBER

SCHLEIFRING was the keynote speaker

at the innovation forum of the “maschi-

nen anlagen verfahren” (mav) trade

magazine in April. In front of an audience

of 300, Dr Mushardt talked about the

SCHLEIFRING Group’s innovative ma-

chining concepts, which provide a com-

petitive advantage through technical and

economic im-

provements. One

of the demands

of the increasing

diversity of work-

pieces and out-

put targets is a

fl exible approach

to the design of

machines and

processes.

Dipl.-Ing. Oliver Wenke is the head of

WALTER’s development center for mea-

suring technology in Garbsen near Hano-

ver, Germany. At the forum for the profes-

sional association of German precision

tool grinders (FDPW) which was held in

parallel to with GrindTec, he talked about

‘Grinding and measuring technology as

guarantees for cost-effective tool produc-

tion’. The qualifi ed engineer spoke about

the utilization of production-related preci-

sion measuring technology in the manu-

facture of precision

tools. WALTER is the

only company to offer

grinding and measur-

ing technology from a

single source. This

company, based in

Tübingen, Germany,

sets the standards

around the world in

this fi eld.

The production of medical instruments

and implants is highly sophisticated.

‘The effi cient machining of extremely

hard materials with stringent demands

on quality is a challenge only the best

can live up to,’ is the verdict of the en-

gineering magazine mav. At their med-

ical colloquium, held in Tuttlingen in

May, Dr Frank Fiebelkorn lectured on

the use of grinding in medical technol-

ogy products. The head of product de-

velopment, research and technology at

STUDER talked

about his com-

pany’s long-

standing expe-

rience in this

fi eld and intro-

duced modular

machine expan-

sion concepts

with the aid of

examples.

Dr Heinrich Mushardt:

Innovative technologies

for the future

Dipl.-Ing. Oliver Wenke:

Measuring technology

guarantees effi ciency

Dr Frank Fiebelkorn:

Modular concepts for

medical technology

Rush of visitors: The SCHLEIFRING Group was pleased with a successful

appearance at this year’s GrindTec

REMOTION

Trade fairs and presentations

In the machine tool sector, the SCHLEIFRING Group is synonymous with leading-edge-technology and innovation. The grinding experts present their know-how at leading trade fairs such as GrindTec and as speakers at specialist symposia.


www.grindtec.de


26 MOTION 02/10


Hi-precision tools for

manufacturing

push-pull connectors

for Ethernet networks

FACTS & FIGURES

The BLOHM PROFIMAT MT in brief

Profi le grinding machine

Grinding spindle output up to 60 kW

Cutting speeds of up to 170 m/ss

Control: Siemens Sinumerik 840D or

Fanuc

‘The BLOHM PROFIMAT MT408 allows us to machine the latest high-tensile steels and com-posites with speed, reliability and accuracy’

Uwe Fiene, Head of Tool Manufacture and

Plastic Tool Construction at Weidmüller

AUTOMATION IN TOOLMAKING

Precision at the touch of a button For the manufacture of indi-vidual parts, the in-housetoolmaking department at Weidmüller relies on thefl exibility and reliability of the BLOHM PROFIMAT MT 408.

Products by Weidmüller, a leading

manufacturer of electrical connec-

tion technology and electronics, based

in Detmold, Germany, can be found

anywhere in the world where energy,

signals and data are connected, trans-

mitted or protected, i.e. in switch pan-

els, trains, photovoltaic systems and

wind turbines or power stations. The

tools required for the manufacture of

terminals, power supplies and PCB com-

ponents for example are made by

Weidmüller’s in-house toolmaking de-

partment. After more than 20 years of

positive experience with JUNG grinding

machines, a BLOHM PROFIMAT MT 408

with Siemens 840D control was added

to Weidmüller’s machine shop at the

end of 2008. Parts for plastic tools, cut-

ting die, bending tools, progressive die and mounting devices are machined on

the PROFIMAT. It replaced a 20-year-old machine another manufacturer could no

longer cope with the increased demands of modern materials. The new BLOHM

PROFIMAT now processes the grinding, measuring and dressing program data

in next to no time, it grinds more accurately and faster and is far more stable than

the old machine.

Andreas Kriegerbarthold, Head of the Center for Grinding Technology in Toolmak-

ing at Weidmüller, explains why a BLOHM machine was chosen: ‘We were espe-

cially impressed by the grinding test. Then there was the machine quality and

last but not least the appearance. The BLOHM PROFIMAT MT 408 fully meets our

requirements. The machine availability is extremely high, the machine provides

the required accuracies of ±5 μm and thanks to its stability, it is able to machine

L_S.26-27_BLOHM_E.indd 26 23.09.2010 15:45:58 Uhr

27MOTION 02/10

works perfectly in the 2-D simulation, thus guarante-

eing that the real machining process will work at the

touch of a button, will the grinding process be started

automatically. The machine operator controls the ma-

chine from a PC. He only has to go to the grinding ma-

chine at specifi ed intervals in order to measure the

workpieces. All measuring data is fed back to the dress-

ing program for any necessary corrections. Dressing

is also carried out continuously during the grinding

process and is fully automatic (Continuous Dressing).

The entire grinding operation therefore becomes a

closed process, consisting of programming, grinding,

measuring and dressing. The experts at Weidmüller

write all the necessary programs themselves. As a re-

sult, the measuring and dressing programs are generated by the grinding programs.

This simplifi es programming for users, since they do not have to learn another

programming language.

Extended automation

Weidmüller is currently implementing one-and-a-half shift utilization of the ma-

chine within single-shift operation: quick grinding tasks are processed during the

day, whereas programs with long run

time are started just before the end

of a shift and carry on automatically

into the night. ‘Of course, this is only

possible because we can completely

rely on the BLOHM PROFIMAT and

our programs,’ explains Andreas

Kriegerbarthold. In future, a robot

loader is to equip the PROFIMAT MT

408 with up to 15 grinding wheels

and 15 workpiece pallets. The grind-

ing machine will then take over not

just the late shift but also the fully

automated night shift.

Satisfi ed faces: Andreas Kriegerbarthold

(Weidmüller, l.) and Joachim Degner

(BLOHM) in front of the new machine

Worldwide use: Weidmüller products are in demand

Increasing demands:

The toolmaking

department at

Weidmüller

manufactures only

individual parts

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

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

+++ w w w . w e i d m u e l l e r . d e + + +

FURTHER INFORMATION

even the latest high-tensile steels and

composites with absolute precision and

reliability. It is compatible with our Leh-

mann dividing head and we can carry

on using the grinding software we have

developed in house.’

Closed process

Weidmüller’s toolmaking department

only grinds individual parts for in-house

use. Each Weidmüller product requires

a special tool. Consequently, the BLOHM

PROFIMAT has to master a completely

new grinding task every time. All test

runs are carried out on the PC for great-

er effi ciency. Only when everything

BLOHM gets top

marks: Grinding

power, machine

quality and

appearance are

impressive

L_S.26-27_BLOHM_E.indd 27 23.09.2010 15:45:59 Uhr

28 MOTION 02/10


INTERNAL GRINDING

Exploiting the strengths

More applications, advanced know-how and a global sales network – two years after its founda-tion, the STUDER Competence Center for Internal Grinding has developed into a success story.

We foresee excellent growth po-

tential and we are securing the

future,’ commented Daniel Huber in

2008 on the merger of STUDER with

Combitec AG to form the STUDER Com-

petence Center for Internal Grinding. The former manager of Combitec and present

head of the center was proved to be right. 2009 was a weak year due to adverse

market conditions but incoming orders are now showing a reversal of the trend.

‘Recent months have already surpassed our best years to date in so far that, by

the end of 2010, we expect to see the highest order volume ever to be achieved

in Biel,’ says Huber.

Product portfolio expanded

The development shows that the merger was the right decision at the right time.

Since 2008, all Combitec machines have gained access to global markets via the

STUDER sales network. ‘At the same time, we have streamlined STUDER’s product

portfolio and considerably increased our grinding know-how in the area of internal

Characteristic: The

key feature of the

precision grinding

machine made in Biel is

the cross-table design

for two or more grinding

spindles which allows

complete machining of

workpieces

Wide range of uses: Workpieces are fully machined

with one clamping operation on the S145

L_S.28-29_STUDER_E.indd 28 23.09.2010 15:46:24 Uhr

29MOTION 02/10

Ceramic parts: Processes and applications are

developed in close consultation with the customer

+ + + a d r i a n . s t u c k i @ s t u d e r .

c o m + + + d a n i e l . h u b e r @

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

FURTHER INFORMATION

INTERNAL GRINDING APPLICATIONS

Applications/Machine CT450(CT450L)

CT550 CT930 CT960 S120 S145 S151

Linear spindle

arrangement up

to 3 (2) spindles

Linear spindle

arrangement up

to 3 spindles

B-axis linear

spindle arrange-

ment up to 3

spindles

B-axis 4-spindle

turret

Z-slide up to 2

spindles

C-axis (optional)

4-spindle turret

4-spindle turret

Closed die X X X

Open die X X

Thread ring gauges X X X X X

Injection molds (e.g. PET bottles) X X

Tool holder (e.g. CAPTO®) X

Collet chucks, reducing bushes X* X* X*

Aerospace components

(e.g. cylinders, gear parts)X X

Medical technology (e.g. balls for hip

joints, knee prostheses)X X X*

Turbine manufacture (e.g. fl anges, wheels) X

Fluid technology (e.g. spreader casings,

valve seats)X (X) (X) X* (X)

Injection technology (e.g. nozzle bodies

and pump bodies for large diesel engines)X X X

Transmission systems X X

hardware platform, harmonization of internal grinding spindles but also uniform

measurement protocols and machine documentation. This will continue to bring

even more benefi ts to our customers,’ explains Huber. The collaboration between

the internal grinding experts in the Swiss towns of Thun and Biel works perfectly.

‘We both benefi t from our ideas, existing structures, procedures and the transfer

of know-how,’ says Stucki. The development of internal grinding processes, new

internal grinding machines and innovative customer applications, for example, is

carried out as a joint venture. The basic machines

are built in Thun and are subsequently equipped

with application-specifi c tools including software

in Biel. The engineers aim to develop the best

possible solution for every application.

grinding with the help of the Combitec

machines,’ explains Adrian Stucki, Head

of Internal Grinding Project Planning at

STUDER (see table below). Since then,

the STUDER Competence Center for In-

ternal Grinding has continued to develop

its position as a market and technology

leader. To this end, the entire internal

grinding program was analyzed. ‘We

have combined our strengths and we are

presently collaborating on a number of

technology projects such as a common

* Batch production with loading system

Range of workpieces: STUDER offers a wide range of

additional internal grinding applications

Wide range of machine concepts: The CT450L CNC internal

cylindrical grinding machine in cross-slide design

L_S.28-29_STUDER_E.indd 29 23.09.2010 15:46:26 Uhr


30 MOTION 02/10

UGT employee Pat Corrigan enjoys divingin his spare time. Together with his family, the 41-year-old explores underwater worlds.

All set for diving:

Pat Corrigan in the

fl ooded gravel pit in

Pennsylvania

HOBBY

Ready to submerge

Water is his element. Pat Corrigan

works as an applications engineer

for the American SCHLEIFRING subsid-

iary United Grinding Technologies

(UGT). He discovered his passion for

scuba diving three years ago. He was

particularly impressed by the dives off

San Carlos in Mexico. It was in this sub-

tropical diver’s paradise in the Bay of

California, that the 41-year-old fi rst ex-

perienced what it feels like to swim with

sea lions and how many creatures live

below the surface of the water. ‘Most people are not even aware of the existence

of the underwater worlds that divers experience,’ explains Corrigan. He was inter-

ested in the idea of diving long before he started working for UGT fi ve years ago.

Finally, during an extended work-related stay in North Carolina, the desire became

so strong that Corrigan took diving lessons after work and passed the exam.

A hobby for all the family

Today, the family man from Millersburg, Pennsylvania, has time to pursue his

hobby two weekends a month. He has already inspired his wife Deana and his

In action: New perspectives open up under water

L_S.30-31_Hobby_E.indd 30 23.09.2010 15:46:49 Uhr

31MOTION 02/10

Preparation is

everything:

Corrigan rechecks

his equipment

prior to the dive

[email protected]

giants on the ocean fl oor. This area boasts several warships, some of which were

sunk during the Second World War. ‘To experience these giants up close while sand

tiger sharks are circling above was particularly exciting,’ says the applications

engineer. This summer, passionate scuba diver Corrigan and his family went on

another exciting dive trip. The destination was Hawaii. This was defi nitely not the

last trip of this kind – since many more underwater worlds are waiting to be dis-

covered by him.

12-year-old son Zachary with his passion

for scuba diving. They regularly join him

on his dives in a local gravel pit. Diving

is not a cheap hobby. The diving equip-

ment alone costs around 3,500 USD.

Each refi ll of the compressed air bottle

costs an additional 12 USD, plus entrance

fees for dive sites where these apply. But

Corrigan thinks it’s worth every cent.

After a stressful day at work, he has

found the perfect balance under water

– and it is available almost anywhere.

He even insists on exploring unknown

waters when on business trips. In 2009,

he used a visit to MÄGERLE to explore

Lake Zurich. ‘In spite of temperatures of

only fi ve degrees Celsius it was worth

it,’ says Corrigan. ‘The crayfi sh there are

even bigger than in the US.’

Shipwrecks and sharks

The Corrigans like active vacations.

While diving off the coast of Wilmington,

North Carolina, they discovered steel

Fully equipped:

Ready to go

L_S.30-31_Hobby_E.indd 31 23.09.2010 15:46:57 Uhr

32 MOTION 02/10


Enthusiastic

experimenters:

Students in front of a

SCHLEIFRING

machine

PORTR AIT OF A UNIVERSIT Y

Research in the Middle Kingdom

The SCHLEIFRING Group has been supporting research work in leading universities formany years. Tongji University in Shanghai, China, has been operating a grinding laboratoryin cooperation with the SCHLEIFRING Group since 2009.

China continues to hunger for ma-

chine tools. The People’s Republic

is still one of the world’s most important

markets for machines. The German for-

eign trade association Germany Trade

and Invest (gtai) reckons that the Middle

Kingdom will import about twelve per

cent more machines in 2010 than in the

preceding year. However, qualifi ed en-

gineers who can operate and maintain high-quality equipment are at least as im-

portant as the machines themselves. According to the German weekly business

news magazine WirtschaftsWoche, some seven million students are currently

studying engineering at 460 technical universities in China. One of these is the

renowned Tongji University in Shanghai..

Joint grinding laboratory opened

In 2009 the state university, in collaboration with the SCHLEIFRING Group, opened

a new grinding laboratory. ‘This facility is a milestone for us, to cooperate with

international market leaders such as the SCHLEIFRING Group and train highly-

qualifi ed engineers,’ says Professor Zhang Weimin, head of the research labora-

tory. He and his students are committed to driving forward innovations for the

SCHLEIFRING Group in the Chinese market through their research and development

work. The SCHLEIFRING Group has provided the laboratory with a K-C33 universal

cylindrical grinding machine and a K-P36 surface grinding machine, both produced

in China. The research is concentrated on:

‘The grinding laboratory is a

milestone for us’Prof. Zhang Weimin,

Tongji University Shanghai

L_S.32-33_Hochschulportraet_E.indd 32 23.09.2010 15:47:25 Uhr

33MOTION 02/10

rameters to guard against thermal damage,’ says Zhang. ‘These include factors

such as the rotation speed of the grinding wheel or the grinding depth.’ Observa-

tional experiments on the K-P36 compact NC give the up-and-coming engineers

detailed knowledge of the grinding process and the technology.

The partnership between the university and the SCHLEIFRING Group also includes

six-month placements for students and job offers for talented young engineers at

KÖRBER SCHLEIFRING MACHINERY SHANGHAI.

+ + + i a m t @ t o n g j i . e d u . c n

+ + + w w w . t o n g j i . e d u . c n + + +

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

FURTHER INFORMATION

TONGJI UNIVERSITY IN BRIEF

Tongji University in Shanghai is one of

the leading state universities in the Peo-

ple’s Republic of China. It was originally

founded in 1907 as Tongji German Med-

ical School. Twenty years later it was

given its present name. The University is

directly responsible to the Chinese Min-

istry of Education. In 2010 it has more

than 50,000 enrolled students and 4,200

lecturers. The faculties of Architecture

and Engineering, in particular, enjoy a

good reputation within the whole of the People’s Republic. As one of the most important

research centers in the country, it has more than twenty-two laboratories and engineer-

ing research bodies at its disposal. In addition, Tongji University maintains six university

hospitals of its own through the campus system.

Forging the new generation: A Tongji University campus

Numerically-controlled precision

grinding

Fault measurement and control

engineering in NC grinding

machines Grinding process mechanisms Measurement of thermal damage

Platform for experiments

As a bridge between theoretical study

and actual practice, Professor Zhang

and his team are currently building up

an experimentation and operation plat-

form. Through experiments on thermal

damage, for example, the students learn

how to recognize its causes and the in-

fl uencing factors. They can then de-

velop preventive measures to avoid it.

‘We have defi ned sensible grinding pa-

L_S.32-33_Hochschulportraet_E.indd 33 23.09.2010 15:47:30 Uhr


34 MOTION 02/10

The new STUDER SERVICE ACADEMYensures that throughout the world ourservice technicians are trained to thehighest standard. This promise is basedon an ingenious concept that guaranteeshigh quality technicians. The aim is quality: The

STUDER service team

with Thomas Aesch-

bacher (left) and Mario

Pfi ster (4th from left)

SERVICE ACADEMY

Ready at all times

Europe, America, Asia – STUDER ma-

chines are used throughout the

world. But what happens when a techni-

cal problem arises and the customer

uses the HelpLine? In an ideal scenario,

fully trained service technicians are on

site without delay and can rapidly diag-

nose and eliminate the fault. STUDER

service technicians are therefore based

locally in order to provide rapid re-

sponse times. In Europe, for example,

they live in carefully selected locations

near to the customers’ machine or pro-

duction sites.

Uniform quality standards

‘We needed a system for qualifi ed training, within the ramifi cations of our ser-

vice network, that would enable us to provide the same services at the same high

level anywhere in the world,’ says Thomas Aeschbacher, Head of Improvement

at STUDER. It was then that the SERVICE ACADEMY was born. ‘The name describes

the training and equipping of our service technicians and agencies,’ explains

Mario Pfi ster, the member of the improvement team responsible for the structure

and organization of the SERVICE ACADEMY. The training given is divided into

fi ve levels (see diagram). ‘We use it to

set high uniform standards.’ Quality

work also depends on the best possi-

ble equipment, for example laptops

that include the STUDER ICOS know-

ledge database and special tools.

‘Ideally, service technicians have an

engineering background,’ explains

Aeschbacher. Even so, there is a long

way to go to reach EXPERT level. All

the service technicians must acquire

additional know-how on top of their

existing knowledge. Mechanical engi-

neering, grinding technology, safety,

EXPERTS IN FIVE STAGES

In the SERVICE ACADEMY, service technicians follow a fi ve-stage training program.

During basic training at the fi rst level they accompany experienced colleagues on visits

to customers. They cannot, and should not, work independently until they have inter-

mediate and advanced knowledge. After building up their knowledge over many years,

service technicians can attempt the EXPERT level. Then they specialize is specifi c fi elds

of engineering.

BASIC ELEMENTARY INTERMEDIATE ADVANCED EXPERT

After 0–1 months After 1–3 months After 3 years 5–6 years After 8 years

Basic

knowledge

Basic

knowledge

Elementary special-

ist knowledge

Advanced special-

ist knowledge

Expert

Junior in basic training Junior Senior

L_S.34-35_Service Kompakt_E.indd 34 23.09.2010 15:47:50 Uhr

35MOTION 02/10

hydraulics, electrics, pneumatics, soft-

ware, accessories and third-party equip-

ment – ‘they have to pass all their per-

formance tests in order to progress to

the next stage,’ says Pfi ster.

Updates in Thun

In addition, all the service technicians

get together once a year in Thun, Switz-

erland. In addition to exchanging experi-

ences, the most important item on the

program is training. The service techni-

cians are given important details on in-

novations, updates and IT. Thus equipped

and trained, they are ready for the next

time the HelpLine phone rings.

+ + + m a r i o . p f i s t e r @ s t u d e r . c o m

+ + + t h o m a s . a e s c h b a c h e r

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

FURTHER INFORMATION

Twice the capacity: The

new STUDER Service

overhauls workshop

OVERHAUL

New from old

STUDER has doubled its capacity for machine overhauls. June saw the

start of work in the new overhauls workshop in Thun, which is now twice

the size it was. ‘We can now restore up to 16 machines at a time to their

original splendor,’ says Jürg von Känel, Head of Overhauls at STUDER Service.

And he means that literally. STUDER machines that leave the Thun factory

after 900 to 1,100 hours of rejuvenation work have the qualities of new

machines. It takes about fourteen weeks to perform a complete overhaul.

‘We strip the machines down to more than 1,000 individual components and

thoroughly inspect every single assembly,’ says Känel. Parts that can be

reused are overhauled by experts. For worn elements, the specialists fi t

STUDER original spare parts exclusively. The service life of the machine is

marked ly extended.

Before: Thousands of production hours have left their

marks on this machine

After: Ready for new jobs. The machine is

bright and shiny once more

[email protected]

L_S.34-35_Service Kompakt_E.indd 35 23.09.2010 15:47:52 Uhr

36 MOTION 02/10


Kai Hölk knows his stuff. He is a graduate of the Univer-

sity of Applied Sciences (HAW) in Hamburg, Germany

and obtained a high average grade of 1.7 in his Mechanical

Engineering Diploma examinations. Hölk not only knows his

theory, he is also familiar with the practice, as he has shown

in his dual study course. During the period when there were

no lectures he worked at BLOHM JUNG and wrote his dis-

sertation. The 24-year-old did so well that on graduation he

was immediately hired and now works in the New Develop-

ments Department.

School visit to BLOHM JUNG

Recently Hölk passed his knowledge on to potential junior

employees. As part of the Natural Sciences & Technology

Initiative (NaT) he showed pupils from the Luisen Gymnasium

(high school) in Hamburg the work of a mechanical engineer

and gave them some everyday tasks to do. One of the jobs

the youngsters did was to determine and calculate the hy-

draulic cylinders for the drive of a new type of grinding ma-

chine. The aim of NaT is to give schoolboys and girls insights

into careers in engineering and encourage them to study

scientifi c subjects. The projects include factory visits, excur-

sions and study units specially developed for school pupils.

Commitment to dual study programs and the NaT initiative

is part of BLOHM JUNG’s promotion of young talent. ‘Both

teachers and pupils think practical integration is a good thing.

For example, the pupils get fi rst-hand experience of the use-

fulness of theory,’ says Bernd Eilers, Head of New Develop-

ments. It is not only the school pupils and students, how-

ever, who benefi t from the young talent program. Industry

gains as well. ‘Projects like NaT contribute to greater numbers

of young people opting for further education on the science

side,’ says Eilers. This could help to counter the skills short-

age in engineering. In addi-

tion, companies have early

contact with talented young-

sters. As was the case, for

example, with Kai Hölk.

Bringing it alive: Graduate engineer Kai Hölk (left), of the New Developments Department at BLOHM JUNG, keeps an eye on pupils from Hamburg’s Luisen Gymnasium as

they tackle a practical problem

INIT IATIVES

A special kind of practical

BLOHM JUNG backs promotion of young talent. The company is committed to dual study courses and promotes the German Natural Sciences & Technology Initiative (NaT).

+ + + b e r n d . e i l e r s @

b l o h m j u n g . c o m + + + w w w .i n i t i a t i v e - n a t . d e + + +

FURTHER INFORMATION

L_S.36_37_ReMOTION_E.indd 36 23.09.2010 15:49:04 Uhr

37MOTION 02/10


A clever software package can also deliver the crucial boost

to productivity in the single item production systems

that are common in tool and die manufacture. For example,

special punch grinding software has been developed for

JUNG’s C and VARIO series machines. This enables more

cost-effective grinding of high-performance stamping tools

for the manufacture of chain plates.

Two punches at a time

The challenges when grinding punches from the blank are

that during the fi rst grinding pass the whole of the compo-

nent is lying on the clamping table. When machining the

opposite side, the workpiece sags be-

cause one side of it is no longer sup-

ported. The required precision can only

be achieved with packing, which takes

time and uses personnel. To bypass this

expensive stage the engineers at

BLOHM JUNG had an idea – two punch-

es are produced at the same time using

a reciprocating plunge grinding proc-

ess. The ‘punch grinding’ software No need for packing: Two punches are ground simultaneously using the reciprocating plunge grinding process

GRINDING SOF T WARE

Up to 60 per cent in-crease in productionMore effi cient manufacture of die punches on the JUNG C and VARIO series.

function provides both process reliability and precision, ir-

respective of whether parts are hollowed out on one side or

on both sides. A depression is ground out on both sides of

the blank. In this manner, the workpiece lies securely during

the entire process and this too ensures precision and an

improved surface fi nish. The fi nished part is then cut apart

down the center. There is no longer any need to spend time

positioning packing. ‘The grinding length is automatically

adjusted and consequently the critical longitudinal run-out

area is untouched,’ explains Thomas Mank, sales engineer

at BLOHM JUNG. In addition, the engineers have used con-

tinuous dressing with the PA37 profi le dresser to reduce the

grinding time by 50 per cent. The result: overall productiv-

ity rose by 60 per cent, precision by 50 per cent and there

was even a 75 per cent improvement in surface fi nish.

Engine chain: Economical grinding of high-performance stamping tools for chain

plates with BLOHM JUNG punch grinding software

Faster, more productive, more accurate: The perfor-

mance of the VARIO series from JUNG is very persuasive [email protected]

L_S.36_37_ReMOTION_E.indd 37 23.09.2010 15:49:08 Uhr

38 MOTION 02/10


Agrowing number of Chinese cus-

tomers are relying on Swiss know-

how for all the machining operations on

bearing rings. MÄGERLE rotary table

grinding machines can grind bearing

rings up to 1.5 meters in diameter with-

out the need to re-clamp and can also

incorporate hard turning of the thrust

faces. The rings will be mainly used in

wind farms, crane systems, earthmovers

and tunnel boring machinery. In the Mid-

dle Kingdom the markets for these tech-

nologies are expanding rapidly. Last year

the installed capacity in the People’s Re-

public rose to 25.8 gigawatts for wind

power alone, according to the Global Wind

Energy Council (GWEC). This put China in

second place, after the USA, in the world

rankings. According to GWEC forecasts,

150 gigawatt wind power stations could be

installed in energy-hungry China by 2020.

Civil engineering is also booming in China,

not least because of economic programs

Increasing demand in the Chinese markets: Special machines from MÄGERLE are being used in signifi cant sectors. These include, above all, renewable energy,

cranes and earthmoving and tunnel boring machines

GRINDING L ARGE WORKPIECES

What size do you want?

Bearing rings of up to 1.5 m in diameter are required. More and more customers in China are using rotary table grinding machines from MÄGERLE to machine these challenging components.

Technology for specialists: A MÄGERLE

rotary table grinding machine with

vertical spindle and integral wheel and

tool changer

L_S.38-39_MAEGERLE_E.indd 38 24.09.2010 10:55:10 Uhr

39MOTION 02/10

spindle is incorporated in

a swiveling unit that is

also an NC axis. The pro-

grammable swiveling

range is ±45° with a re-

peating accuracy of ±3

angular seconds. The

coolant nozzle that is

mounted on the grinding

spindle is also program-

mable and can be moved

into any desired radial

position. The advantage

of this is that the coolant

is always used to maxi-

mum effect. Wheels with

different geometries are

profi led on the table by

means of a diamond disc

using the CNC control. Modifi cation and correction of the desired profi le is simple,

effi cient and accurate.

Increasing market potential

‘In rotary table grinding machines the trend is increasingly towards machines with

table diameters of up to four meters,’ says Tschopp. Demand continues to rise. Re-

newable energies alone have a strong tailwind. According to data from Bloomberg

business services, world investment in forms of renewable energy rose by 31 per

cent in the fi rst quarter of 2010 compared with the same period in 2009. Experts

expect a global investment volume of

between 120 and 140 billion euro for the

whole of 2010. In the last year the fi gure

was 115 billion euro.

and additional infrastructure projects.

The comprehensive list of projects in-

cludes hydraulic engineering, construc-

tion of new airports and the extension

of the road and rail network.

Sturdy, precise and versatile

Chinese customers opt to use MÄGERLE

rotary table grinding machines above all

because of their high sturdiness, versatil-

ity and their precision engineering. ‘The

machine has vertical swiveling spindles

and automatic grinding wheel and tool

changers, so that the workpiece only

needs to be clamped once to grind the

internal and external diameters and race-

ways. This improves both productivity

and cost-effectiveness. A lathe tool can

be automatically loaded, so thrust faces

can also be hard turned without the need

to re-clamp,’ says Max Tschopp,

MÄGERLE sales engineer for China. The

changeover time for wheels or tools is

around 10 to 15 seconds.

The rotary table machines are based on

the well-proven MÄGERLE traveling col-

umn design with non-wearing hydro-

static wraparound guideways (X and Y

axes). These provide smooth running,

stability, vibration damping and the abil-

ity to withstand the highest loads. ‘The

console for the holding fi xture is mount-

ed on the machine bed with the traveling

column,’ explains Tschopp. ‘In the axial

direction, a preloaded hydrostatic wrap-

around guideway ensures that the ma-

chine runs with the required smoothness

and precision. Radial forces are absorbed

by highly accurate spindle bearings and

the table is driven by a water-cooled

torque motor.’ The table can thus turn

continuously or, alternatively, be highly

accurately indexed.

One clamping stage, many

operations

Thanks to this combination and the ver-

satile grinding wheel and tool changer,

customers can perform a large number

of very varied operations on large, high-

precision workpieces while only clamp-

ing them once. The vertical grinding

Precision: MÄGERLE

rotary table machines are

based on the well-proven

traveling column design

+ + + m a x . t s c h o p p @ 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 + + +

FURTHER INFORMATION

Tool changer: Internal and

external diameters are

ground without reclamping

the workpiece

L_S.38-39_MAEGERLE_E.indd 39 24.09.2010 10:55:26 Uhr

40 MOTION 02/10


Meeting: Ivo Kozel (left of noticeboard) and Jozef Vlasác (right of noticeboard) pass on important information

to the staff

The faces behind the machines: WALTER has been producing

machines in Kurim in the Czech Republic since 1996

REPORT

A day in Kurim

Customers from all over the world order machines from WALTER. The high-tech products are produced in Kurim, the company’s Czech competence center.

Kurim near Brno is a picturesque little

town with just under 10,000 inhabit-

ants, in an idyllic setting surrounded by

green hills. At fi rst glance you would not

suspect that this provincial location is a

stronghold of Czech machine tools pro-

duction. The SCHLEIFRING Group is

here, represented by Walter Kurim s.r.o.

The company sends machines all over

the world from this location. Its 150 em-

ployees produce up to 500 of them per

year. MOTION reporter Oliver Haastert

spent a day behind the scenes at the

Kurim plant.

9 a.m. Production meeting:

Quality Manager Ivo Kozel and Produc-

tion Manager Jozef Vlasác hold their

daily meeting with the employees. They

pass on current information, defi ne the

as-is and target situation and discuss resource allocation. ‘In this way we ensure

that the staff can work independently,’ says Jozef Vlasác.

L_S.40-44_Reportage Kurin_E.indd 40 29.09.2010 15:05:52 Uhr

41MOTION 02/10

11.15 a.m. Logistics: In Kurim, WALTER has a fully automatic small parts

warehouse. The ten-meter-high shelves contain the parts needed to produce the

various WALTER machines. The machine factory staff also send spare parts from

here all over the world – and it’s faster than you might think: ‘If an order comes in

before 4 p.m. we send the parts out the same day,’ says Gerhard Riester, Head of

Production and Purchasing.

Midday, lunch time: The

plant canteen serves gener-

ous helpings of rice and a

juicy chop. The staff hold a

relaxed discussion of the

day’s events. Managing Di-

rector Franz Dettling also

enjoys the good simple food.

Born in Swabia in Germany,

Franz Dettling has lived in

the Czech Republic for six

years, and still feels very

comfortable here.

1.40 p.m. Pre-assembly: The modules pre-assembled here are not

yet specifi c to particular orders and can be used in any type of machine. The work-

ers check thoroughly that each element is fi tted correctly.

2.10 p.m. Multi-station production line: Production is centered around

two multi-station production lines. Every machine built here already has a cus-

tomer waiting for it. A complete machine takes eight days to build. ‘The processes

9.45 a.m. Organization: The ad-

ministrative offi ce, the plant’s control

center, is a hive of activity. The tele-

phones ring while the offi ce staff bus-

ily process new orders from the com-

pany’s head offi ce in Tübingen. This is

where the machines start to come into

being. Once the necessary formalities

and plans are complete, the way is clear

for production to start.

10.35 a.m. Quality control: ‘We

don’t leave anything to chance,’ says

Quality Manager Ivo Kozel. ‘We carry

out quality checks at every stage of the

process chain. This means we can guar-

antee that the machines leave our plant

in top condition.’ The quality controls

start by measuring the supplied parts.

They can only be considered for use on

a WALTER machine if they are 100 per

cent accurate.

A new order: The machine begins life in the

administrative offi ce

In the beginning was the measuring: The employees

check the supplied parts extremely thoroughly

Pre-assembly: Each element must be fi tted correctly before a subassembly can be sent to the production line

Lunch break: The employees eat in the works canteenLunch break: The employee t i


42 MOTION 02/10


to be carried out each day and at each

station are clearly defi ned,’ explains

Jozef Vlasác, the production manager.

‘The advantages of this approach include

transparency, standard, clearly defi ned

jobs and clearly defi nable quality crite-

ria, which reduces processing times.

Any faults can be spotted sooner and

rectifi ed,’ the Slovakian engineer adds.

3.45 p.m. Final inspection: A

machine is almost ready. Just a few

more grinding and function tests and

visual examinations for defects and the

new WALTER is ready for delivery.

5.30 p.m. Delivery: As soon as the

machine is packed, it can be delivered

to customers anywhere in the world. WALTER employees Petr Scudla, Jakub

Doležel and Jaroslav Sevcik are visibly proud of their handiwork. A forwarding

company transports the fi nished machine direct to the customer.

6 p.m. Home time: It’s the end of the shift for the 150 employees. Managing

Director Franz Dettling takes one last look from his offi ce into the factory work-

shop. Satisfi ed, he says goodbye to the staff and works through a few last e-mails.

Does he miss his home after all these

years in Kurim? ‘You know,’ he an-

swers with a smile. ‘Once you visit

the Czech Republic, you never want

to leave.’

+ + + f r a n z . d e t t l i n g @ w a l t e r -

m a c h i n e s . d e + + + i n f o . w c z @

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

FURTHER INFORMATION

Clear quality criteria: Multi-station assembly reduces

processing times

Ready for delivery (right to left): Petr Scudla, Jakub

Doležel and Jaroslav Sevcik in front of a

HELITRONIC POWER

Final inspection: Checking that everything works as

it should

Multi-station production line: A machine passes

through eight stations before it is complete

BRNO AT A GLANCE

Population: 370,000 (sec. largest city

in the Czech Republic)

Exhibition center: With annual sales of

40 million euros, the

largest exhibition

center in eastern

Central Europe

Educational

establishments: Six universities,

including the Brno

University of

Technology with

18,000 students

Museums: Technical Museum

Prague

i embly reduces

Vienna

Brno

Bratislava


43MOTION 02/10

Form grind-

ing on

STUDER ma-

chines is now

even more

precise thanks

to a new mo-

tor spindle for

the workhead.

The synchro-

nization system reduces the temperature rise of the mo-

tor spindle and this leads to greater precision. The load

can be increased during live grinding operations and

hence heavier workpieces can be accommodated. The

compact design of the motor spindle saves space and

optimizes geometrical alignment.

SC H A U D T

MIKROSA

has developed

SPEED-LOAD – a

loading system

for the Cam-

Grind L, in coop-

eration with

Ads-Tech. Us-

ing this loader

when manufacturing camshafts, the shafts can now

be changed in fi ve seconds instead of the ten seconds

needed before. A special feature is that the shafts are

positioned before the gripper picks them up. Thus

they are already in the correct position for grinding

the cams. In addition, the cams can be deburred by

an additional unit.

Lightning speed: The CamGrind L shortens

changeover times

NEW MOTOR SPINDLE

Precise form grindingLOADING SYSTEM

Changeover time halved

COMBINED SOF T WARE TOOLS

Right at the outset

Spot on: The new motor spindle gives precision

NEWS TO USE

Practical tips for your processes The StuderWIN operating and programming software, a modern loading system for the SCHAUDT CamGrind L and the new STUDER motor spindle are just some of the useful offerings from the SCHLEIFRING Group – that you can fi nd on this page to meet your everyday manufacturing challenges.

[email protected]

[email protected] [email protected]

Typically, production machines have had to be operated from a separate

terminal for each additional component but now, with the StuderWIN

operator interface all additional equipment can be controlled from a very

user-friendly 15" touch screen. Many users fi nd it easy to work with

StuderWIN as it uses the largely familiar Windows environment. The

StuderWIN operating and programming software has other special features.

All the software tools developed by STUDER for form grinding, thread

grinding and profi le grinding and dressing can be called up directly with

StuderWIN as an ‘integral’ part of the machine control, simply by pressing

a button. The programs generated are stored where they are used. This

prevents operator error and encourages economical working. StuderTech-

nology integrated is a newly developed platform and is fully integrated in

the StuderWIN programming environment. The operator thus has easy ac-

cess to the required functions on the machine.

StuderWIN

StuderTechnology integrated (Option Pictogramming)

StuderDress integrated

StuderContour integrated

StuderThread integrated

StuderForm integrated

StuderFormHSM integrated

Clear features: The StuderWIN user interface

is easy to use


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 201814ChinaPhone +86–21–395873–33Fax +86–21–395873–[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 +86–10–650065–[email protected]


(Shanghai) Co. Ltd.

Wuxi Branch Offi ce

A-096 YangmingHi-Tech Industrial ParkWuxi Jiangsu 214024, ChinaPhone +86–10–852610–40Fax +86–10–650065–[email protected]


(Shanghai) Co. Ltd.

Chongqing Branch Offi ce

Room 17-03 AMetropolitan Tower 68Zou Rong Lu, Central DistrictChongqing 400010, ChinaPhone +86–23–637036–00Fax +86–23–637410–[email protected]


(Shanghai) Co. Ltd.

Guangzhou Branch Offi ce

Room 2003, 20/FCenter Plaza Tower B161 Linhexi Rd.Tianhe District GuangzhouGuangdong Province 510620, ChinaPhone +86–20–386212–41Fax +86–20–386212–[email protected]

United Grinding

Technologies Inc.

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

United Grinding

Technologies Inc.

5160 Lad Land DriveFrederiksburgOH 45342, USAPhone +1–937–859–1975Fax +1–937–859–[email protected]

Körber Schleifring GmbH

India Branch Offi ce

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

Mägerle AG Maschinenfabrik

Allmendstrasse 508320 Fehraltorf, SwitzerlandPhone +41–433–5566–00Fax +41–433–5565–[email protected]

Blohm Jung GmbH

Kurt-A.-Körber-Chaussee 63–7121033 Hamburg, GermanyPhone +49–40–7250–02Fax +49–40–725032–[email protected]

Blohm Jung GmbH

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

Fritz Studer AG

3602 Thun,SwitzerlandPhone +41–33–43911–1Fax +41–33–43911–[email protected]

Schaudt Mikrosa GmbH

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

StuderTEC K.K.

Matsumoto Bldg 2F4-10-8, Omorikita Ota-ku,Tokyo 143-0016, JapanPhone: +81–36801–6140Fax: +81–36662–[email protected]

Walter Maschinenbau GmbH

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

Walter Machines

Asia-Pacifi c Ptd. Ltd.

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

Ewag AG

Industriestrasse 44554 Etziken, SwitzerlandPhone +41–32–61331–31Fax +41–32–61331–[email protected]

Körber Schleifring UK Ltd.

B 13 Holly Farm Business ParkHoniley, Kenilworth, Warwickshire,CV8 1NP, Great BritainPhone +44–19–264850–47Fax +44–19–264850–[email protected]

Walter Kurim s.r.o.

Blanenská 128966434 Kurim, Czech RepublicPhone +420–541–4266–11Fax +420–541–23195–[email protected]

Walter Machines Italia s.r.l.

Via G. Garibaldi, 4222070 Bregnano (CO), ItalyPhone +39–031–7708–98Fax +39–031–7760–[email protected]

Walter Japan K.K.

1st fl oor MA Park BuildingMikawaanjo-cho 1-10-14Anjo City, JapanPhone +81–556–71–1666Fax +81–566–71–[email protected]

Schleifring Brasil Ltda.

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

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