grinding machine magazine - job shops

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job shopsINDUSTRY FEATURE

also in this issue . . .

Experience THE POWER, A Rise to Power page 16

Experience THE PARTNERSHIP, Partners in Grinding Productivity page 24

Experience THE PASSION,Shop Propagates a Passion for Grinding page 28

page

20

2,100+ YEARS EXPERIENCE page 4

SUPPORT OPPORTUNITIES page 47

THE AMERICAN SPIRIT LIVES IN TODAY’S JOB SHOPS page 3

2 CAREER TRACK

3 MY THOUGHTS

4 GRINDING IN MOTION

14 A GLIMPSE INTO

34 OPTIMIZE

40 IN THE ZONE

46 DIGITAL DIGEST

47 LAST THOUGHT

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GQ/Job Shops Issue 2014 1

D E P A R T M E N T S

page 28

page 24

page 16

F E A T U R E S

7 Modular Hose Nozzles Streamline Small Batch Grinding Setups How nozzle configuration improves the grinding process

10 Expertise Drives Expansion Thomas Wire Die builds for specialty, precision applications

16 A Rise to Power The 20-year history of the HELITRONIC POWER

20 Experience UNITED GRINDING at IMTS A glimpse into the technology on display at IMTS 2014

24 Partners in Grinding Productivity Manufacturers experience increased productivity when partnering with OEMs such as UNITED GRINDING

28 Shop Propagates a Passion for Grinding Midwest shop introduces advanced ID/OD grinding technology to grow business

36 The Evolution of Grinding Technology Understanding grinding technologies and advances through the years

2 GQ/Job Shops Issue 2014 GQ/Job Shops Issue 2014 3

IMTS is the largest and longest-running manufacturing

technology trade show held in the United States. Did you

know it’s also an exciting opportunity for the future workforce

of America to learn more about the industry and the high-tech,

well-paying careers it offers?

The Association for Manufacturing Technology (AMT) is

working hard to build the Smartforce of tomorrow, and has

a longstanding tradition of gathering middle school, high

school and college students, educators, administrators

and parent chaperones at IMTS to experience advanced

manufacturing technology.

At this year’s show, AMT is hosting the Smartforce Student

Summit, which features interactive displays from leading

national education organizations, manufacturing technology

providers, career and technical schools, community colleges,

and engineering schools.

The Summit, which is free for registered schools, gives

students a unique chance to have direct contact with the

industry professionals whose minds move manufacturing

forward. It also allows young people to interact with exciting

new innovations in today’s manufacturing industry so that they

can translate their science, technology, engineering and math

(STEM) education into real-world careers.

The U.S. manufacturing industry is one of the most exciting,

innovative and vibrant places to build a career. As many

companies struggle to find the skilled employees they

need, IMTS and the Summit are bringing together industry

and education to help generate tomorrow’s Smartforce

that will keep the United States in its global manufacturing

leadership position.

Learn morewww.imts.com/student

CAREER TRACK

Smartforce Student Summit

UNITED GRINDING North America510 Earl Blvd. Miamisburg, OH 45342, USA Tel +1-937-859-1975 Fax +1-937-859-1115 [email protected]

Fredericksburg Branch Office 5160 Lad Land Drive Fredericksburg, VA 22407, USA Tel +1-540-898-3700 Fax +1-540-898-6819 [email protected]

United Grinding Mexico S.A. de C.V. Blvd. Bernardo Quintana No. 7001 Of. 1003 Querétaro, Qro. 76079, Mexico Tel +52-1-555-509-7739 [email protected]

CYLINDRICAL Hans Ueltschi Vice President, Sales 510 Earl Blvd. Miamisburg, OH 45342, USA Tel +1-937-859-1975 Fax +1-937-859-1115 [email protected]

TOOL Markus Stolmar Vice President, Sales 5160 Lad Land Drive Fredericksburg, VA 22407, USA Tel +1-540-898-3700 Fax +1-540-898-6819 [email protected]

SURFACE & PROFILE Larry Marchand Vice President, Sales 510 Earl Blvd. Miamisburg, OH 45342, USA Tel +1-937-859-1975 Fax +1-937-859-1115 [email protected]

CUSTOMER CARE Joseph Szenay Vice President, Customer Care 510 Earl Blvd. Miamisburg, OH 45342, USA Tel +1-937-847-1234 Fax +1-937-859-6915 [email protected]

the GRIND Publisher Ted Neckel Director of Corporate Marketing [email protected] Tel +1-937-847-1229

Layout & Design dgs Marketing Engineers

© 2014. All Rights Reserved.

UNITED GRINDING Group InternationalKörber Schleifring Machinery (Shanghai) Co., Ltd. 1128, Tai Shun Road Anting Town Jiading District Shanghai 201814, China Tel +86-21-3958-7333 Fax +86-21-3958-7338 [email protected]

Körber Schleifring Machinery (Shanghai) Co., Ltd. Beijing Branch Office Room 202, Building 18 Tower B, Universal Business Park No.10 Jiuxianqiao Road Chaoyang District Beijing 100015, China Tel +86-10-8526-1040 Fax +86-10-6500-6579 [email protected]

Körber Schleifring Machinery (Shanghai) Co., Ltd. Chongqing Branch Office 15-11 Building 4, No.18 Jinshan Road, Longxi Street, Yubei District, Chongqing 401147, China Tel +86-23-6370-3600 Fax +86-23-6374-1055 [email protected]

Körber Schleifring Machinery (Shanghai) Co., Ltd. Guangzhou Branch Office Room 2003, 20/F Center Plaza Tower B 161 Linhexi Road Tianhe District Guangzhou 510620, China Tel +86-20-3862-1241 Fax +86-20-3862-1270 [email protected]

United Grinding GmbH India Branch Office No. 487 - D1 & D2A 4th Phase, KIADB Main Road Peenya Industrial Area Bangalore 560058, India Tel +91-80-415-54-601 Fax +91-80-415-54-603 [email protected]

United Grinding GmbH Moscow Office 1-j Kasatschij Pereulok 5/2, Strojenije 1 119017 Moskau, Russia Tel +7-495-956-93-58 Fax +7-495-956-93-59 [email protected]

The American Spirit Lives in Today‘s Job Shops.

M Y T H O U G H T S

Terry Derrico

President and CEO,

United Grinding North America, Inc.

I admire people who run job shops. They are highly skilled individualists who meet

the demands of complex, difficult projects and possess the creativity and tenacity

to devise the most beneficial design solutions. The backbone of their business

relies on their dedication to improving productivity for their end users. I believe

that job shop entrepreneurs epitomize the American spirit and are at the heart

and soul of North American manufacturing.

Many of today’s large manufacturers started as job shops, including several

companies in The UNITED GRINDING Group. Fritz Studer, founder of STUDER,

originally founded a job shop making tooling for the watch industry. To improve

the quality of his tooling, he built a grinding machine, and from there, STUDER

grew to become the leader in cylindrical and form grinding. BLOHM has a

similar story, starting as a small company that made measuring instruments

and apparatus for the construction industry. When the company needed a

grinder, they designed and built a grinding machine that changed the focus

of the company.

I am encouraged by the direction in which North American manufacturing is

headed. Large manufacturing corporations are increasingly depending on job

shops to solve their machining problems and fulfill their specialty needs.

They are working together in dynamic relationships to drive productivity

through creative and cost effective solutions.

While I believe we are seeing heightened interest in

manufacturing, we must ratchet up the momentum and

do all we can to champion this constantly evolving and

rewarding industry. The American spirit is alive and well

in today’s job shops, and we must do all we can to

preserve it.

“Job shop entrepreneurs epitomize the American spirit.

I believe they are the heart and soul of North American manufacturing.”

4 GQ/Job Shops Issue 2014GQ/Job Shops Issue 2014 5

The Grinding in Motion department typically spotlights the latest and greatest trends in the manufacturing industry —information that can move your company forward. As a special feature for the IMTS issue, we would like to introduce readers to members of the UNITED GRINDING team. Individuals, who like our technology, provide solutions that continuously propel our customers forward. Together, the UNITED GRINDING sales, service and support teams provide more than 2,100 years of combined EXPERIENCE. When you begin a PARTNERSHIP with us, you will witness the PASSION of our employees and the POWER of the eight brands that support our three product technology groups.

Hans UeltschiVice President35 Years

William CramRegional Sales Manager 37 Years

Mike HeadInside Sales Manager25 Years

Don Hayes Project Manager24 Years

Tom VieiraApplications Manager34 Years

Joe Kinder Applications Engineer6 Years

Doug EmersonRegional Sales Manager28 Years

Gerd StaadtProduct Manager9 Years

Tom DunnProject Engineer6 Years

Uli AchillesApplications Engineer35 Years

Doug KringApplications Engineer7 Years

Gene HallmanRegional Sales Manager17 Years

Andrew OsbornProduct Engineer2 Years

Casper HaganProject Engineer31 Years

Bob BealsApplications Engineer29 Years

Jim LennonApplications Engineer25 Years

Ryan MichelsRegional Sales Manager17 Years

Ken ReisenbuchlerProject Engineer35 Years

Peter DietzApplications Engineer34 Years

Chris SaranasApplications Engineer7 Years

Nick SchuetzRegional Sales Manager35 Years

Brian JacksonApplications Engineer17 Years

Kristopher WoodwardApplications Engineer11 Years

Michelle Mock Sales Support Engineer3 Years

C Y L I N D R I C A L D I V I S I O N

Jerry MasonField Service Manager15 Years

Kevin SellmanField Service Manager3 Years

Markus StolmarVice President14 Years

Dan BelliveauRegional Sales Manager42 Years

Kevin HoulihanSales Support Engineer25 Years

Simon BramhallProject Manager28 Years

Simon MannsApplications Manager27 Years

Harold TuttleField Service Manager19 Years

Eric KangailRegional Sales Manager25 Years

Alex BoswellProject Engineer20 Years

Ben BurchellApplications Engineer10 Years

Kevis MitchellField Service Manager3 Years

Bruce MorseRegional Sales Manager24 Years

Jason BryantProject Engineer17 Years

Paul EhrlichApplications Engineer22 Years

Matt BeemField Service Manager4 Years

Gary WimbleRegional Sales Manager26 Years

Larry WilsonProject Engineer31 Years

Ron GrimesApplications Engineer25 Years

Mike MancusoField Service Manager13 Years

Andrew AllwoodInside Sales Manager35 Years

Kyle HallApplications Engineer18 Years

Frank TemplinField Service Manager36 Years

Peter BeaupreAccount Manager25 Years

Michael HilbertApplications Engineer15 Years

T O O L A N D M E A S U R E M E N T D I V I S I O N

David HunekeApplications Engineer20 Years

Stefan KrannitzApplications Engineer20 Years

Andrew WalentaApplications Engineer25 Years

Matt YantzApplications Engineer27 Years

Frank LynchTechnical Advisor44 Years

Charles MichieField Service Manager24 Years

Robin WhittonField Service Manager11 Years


component manufacturers in high-production environments can often invest a significant amount of time setting up grinding processes for long runs. While at the opposite end of the spectrum, the typical job shop must

quickly change over from one grinding process to the next on a daily basis and meet the same high part qualities as the OEMs. In these instances, plastic modular coolant hoses, such as Loc-Line®, provide successful nozzle systems for cooling and lubricating manufacturing processes.

How nozzle configuration

improves the grinding process.

By Dr. John A. Webster,

Consultant and Manufacturer

Cool-Grind Technologies

F E A T U R E

Modular Hose Nozzles Streamline Small Batch Grinding Setups

A tool and cylindrical grinder fitted with plastic modular hose nozzles.

Larry MarchandVice President30 Years

Robby FaulknerAccount Manager30 Years

Kayleigh Fisher Project Manager11 Years

Reinhard KoppenApplications Manager41 Years

Mike MartinRegional Sales Manager38 Years

Baltz KloetiProject Manager40 Years

Don GeigerApplications Engineer23 Years

Greg SorgeRegional Sales Manager23 Years

Tom RexProject Manager2 Years

Jon HollowayApplications Engineer23 Years

Phil WissRegional Sales Manager22 Years

Gerry HeineProject Engineer36 Years

Tim OrsteadApplications Engineer39 Years

Shane MusgroveInside Sales Manager20 Years

Gregory JohnsonProject Engineer19 Years

Matt SimmonsApplications Engineer15 Years

Robert UrenApplications Engineer28 Years

S U R F A C E A N D P R O F I L E D I V I S I O N

Joseph Szenay Vice President20 Years

Jeff FoleySenior Field Service Manager34 Years

Michael BoeschField Service Manager20 Years

Pat CorriganField Service Manager9 Years

German GordilloManaging Director25 Years

Abraham SeguraField Service Manager7 Years

Carlos OrtegaField Service Engineer2 Years

Francisco GuerreroField Service Engineer1 Year

With 48 employees and 456 years of combined experience,

the UNITED GRINDING Customer Care Team provides everything

from field service to support to training to spare parts.

M E X I C O

C U S T O M E R C A R E

The short modular elements and high 30˚ swivel angle per joint mean easy aiming of the jet. Additionally, the internal flow diameter as compared to the outer diameter of the system is very generous, allowing for minimal drop in pressure. The pre-load between the ball and socket of adjacent elements provides enough friction to keep the hose in place at the moderate pressures used in machining processes.

Elements can be added and removed to change the system’s length. And, a large range of nozzles, valves and fittings are available to connect it to any threaded port or change the flowrate and width of coverage to suit the application.

With grinding wheel peripheral speeds being much higher than the peripheral speeds found in machining processes, the air boundary layer surrounding the wheel must be overcome to wet the wheel and transport the coolant through the process. Pressures from 60 to 100 psi are required to achieve the best process cooling. By more closely matching the grinding wheel speed with the jet speed, manufacturers experience reduced thermal damage, better wheel life, higher throughput, a cleaner wheel surface, less wheel dressing and better surface finishes.

When using plastic modular hose for grinding, several factors should be kept in mind:

• The reaction force from the jet can cause the hose to move out of position. This problem becomes more prevalent as the

elements wear, due to ingress of grinding grit and workpiece chips into each joint.

• The rapid hydraulic shock associated with the solenoid valve opening at the start of the cycle can cause the elements to detach.

• While one modular hose manufacturer does supply element clamps, not all of the popular catalog companies have them available.

• Larger nozzle apertures are generally chosen to keep the pressure low, even if the pump is capable of more.

• Operators may have to reduce flow rate with a valve (also lowering pressure at the nozzle) to control machine bed draining.

• There is a greater fire risk with oil coolants if a nozzle moves over time.

Given the above factors, shops can employ some simple engineering principles to enhance plastic hose system performance:

• Hard plumb from the manifold to within 4" of where the nozzle tip will be placed. Then, fit only three or four modular hose elements before the nozzle. This is necessary because jet reaction force creates the greatest torque where the nozzle system attaches to the coolant manifold. And, a steel nipple can resist it better than a modular hose element.

A STUDER cylindrical grinder with 50-psi-rated, thumb-locked clamps and coherent-jet nozzles.

A JUNG profile grinder with 100-psi-rated socket-head screw clamps and adjustable telescopes.

CyClotron ProduCts, InC.

Visit our website: www.cyclotronproducts.com

Cyclotron Products, Inc. offers a complete line of filtration systems designed to remove solid particles from water soluble and synthetic industrial fluids using the most economical and efficient methods.

Leaders in Filtration Systems

CYCL

ONIC FILTRATION

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Enviromentally ResponsibleCyclonic filtration benefits the environment as

no disposable media is used in the process. This saves petroleum, preserves countless trees, and eliminates the associated environmental

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A range of nozzles and adjustment hardware integrate with the standard Loc-Line modular hose system to make it much more suitable for high-performance grinding.

• Fit clamps onto each element regardless of whether it is straight or bent. Hydraulic shock can still make the nozzle move over time, especially when higher pressures are used.

• Fit nozzles with apertures on the smaller side of the range to boost the pressure. Use coherent-jet nozzles for better air barrier removal. The added benefit of lower flow rate is reduced turbulence and pressure drop, due to the undulating internal profile of the modular hose.

• Resist the urge to add and remove elements by considering the range of movement needed. With greater grinding wheel diameter extremes, such as in cutting tool or surface grinding, a simple telescoping system may need to be installed to adjust the nozzle aim.

• Minimize the number of fitted nozzles, as each one will lower the overall coolant pressure.

An existing nozzle system for high-performance grinding can easily be re-configured to a modular hose design with the addition of several enhancements.

Dr. John A. Webster is owner of Cool-Grind Technologies, which specializes in the supply of generic and custom coolant nozzles for grinding.

Learn morewww.cool-grind.com



By Jim Anderton, Editor

Canadian Metalworking

Thomas Wire Die builds for specialty, precision applicationsshop can grow its business in many ways. One proven path involves steady expansion based on a foundation of expertise. The consistent growth of Thomas Wire Die Ltd., Burlington, Ontario, is a good example. Founded in 1966 to produce and service small tungsten

carbide wire dies, the company built on its experience in making precision parts from hard materials and used it to expand its range of products and customers. And through its nearly 50 years in operation, the shop has continually updated its manufacturing technology to enable it to take full advantage of its special skills.

Wire drawing dies are the shop’s original product and continue to be an important part of the business. A typical die is composed of a steel casing that holds a carbide component with a hole through which wire material is drawn. “We buy carbide and steel as raw materials and we machine the steel casing, grind or EDM the carbide, then assemble them into a tool and finish it,” said Adam Thomas, vice president of Thomas Wire Die as well as grandson of the company’s founder.

If the die aperture is round the shop grinds it; if it is square or another shape it is machined via EDM. Part sizes include casings as large as 16" OD that hold a carbide insert with a 12" diameter; among the smallest part features produced are 0.005"-diameter holes in natural diamond wire drawing dies.

As time passed, Thomas Wire Die began to produce larger carbide wire and cable dies, then added dies used to cold finish round bar and to draw square, hex and other shapes of bar and tube. Expansion continued with the manufacture of carbide punches and shape dies for forming, stamping and deep drawing, as well as tube drawing plugs and mandrels.

Taking further advantage of its longtime familiarity with the challenges of processing hard carbide parts, Thomas Wire Die moved into engineering and producing carbide wear components. The custom parts combat corrosive and abrasive wear in industrial applications ranging from agriculture to aerospace. “In wear components, we look for opportunities where we can get people to switch from using tool steel to carbide,” Thomas said. “Carbide can provide five times the life of the tool steel. Our customers used to replace a tool steel part every month, now they replace it every six months.”

F E A T U R E

Expertise Drives Expansion“In wear components, we look for opportunities

where we can get people to switch from using

tool steel to carbide ... Carbide can provide five

times the life of the tool steel. Our customers

used to replace a tool steel part every month,

now they replace it every six months.”

According to Adam Thomas, vice president at Thomas Wire Die, the STUDER CT750 allows the company to produce a more consistent, uniform product.

Part sizes include casings as large as 16" OD that hold a carbide insert with a 12" diameter; among the smallest part features produced are 0.005"-diameter holes in natural diamond wire drawing dies.

As the shop expanded its offering of services, it continually augmented its skills with the addition of new manufacturing technology including EDM, turning and milling machines, and advanced CNC grinders that enabled it to serve its traditional markets better and move into new ones.

A notable addition was the company’s 2006 acquisition of Stoney Creek Precision Parts, a machine shop and manufacturer of cold-heading dies used to form bolts and similar products. Thomas Wire Die made the acquisition to help it grow its business in the cold-heading die market and strengthen its machining capabilities.

About three years ago, Thomas Wire Die looked for ways to reinforce its capabilities in the ID grinding that is still the basis of the company’s business. “We grind ID every day, all day, and we asked ourselves what piece of equipment would help us be better in that product,” Thomas said. “We weren’t trying to get into a totally new area; it was work that we already had and we wanted to move it on to a machine that was more efficient and produced higher quality, higher precision and better parts.”

Subsequently, the company acquired a STUDER CT750 radius ID grinding machine for hard materials in 2011. The machine has a CNC-controlled B-axis with an automatic swiveling range from +60º to -91º. An oscillating grinding wheel enables it to produce an unlimited number of different radii up to 90 degrees. A modular turret with two grinding spindles provides great flexibility in the machining of individual parts as well as large-scale production. The machine handles small- to

medium-size workpieces, with X- and Z-axis travels of 14" and 10" respectively, a grinding length of 4", and a maximum ID grinding diameter of 3".

“Part of what prompted us to look at the STUDER machine was to reduce cycle times and be more competitive on the pricing side,” Thomas said.

The machine’s CNC technology and structural rigidity ensure the production of a good grinding surface finish. Surface finish is critical in diemaking because it is the basis for final polishing. “The STUDER machine allows us to get a better surface finish faster than we could before, and reduces polishing by hand,” Thomas said, noting that excessive polishing can distort a part’s geometry.

The STUDER grinder also has in-process gaging capability that helps reduce cycle times. The probe measures the part during the rough grinding process and adjusts the operation to leave a minimum amount of material for finish grinding. Because finish grinding is slower than rough grinding, minimizing finishing passes reduces cycle times overall.

The machine’s CNC capabilities also boost part consistency. Previously, for example, reworking a wire die involved changing its contours via manual grinding. Now the shop can program an exact radius. “The STUDER machine allows us to produce a more consistent, uniform product,” Thomas said. “In the past when we ground the parts by hand, we might get a few tenths difference on the size. Now, we can sell a die today, and sell that same die a month from now, and it is exactly the same geometry. The customer knows the dies are identical.”


“The STUDER machine allows us

to get a better surface finish faster

than we could before, and reduces

polishing by hand,” Thomas said,

noting that excessive polishing

can distort a part’s geometry.

Thomas Wire Die acquired its first STUDER CT750

in 2011 to perform radius ID grinding. The company

recently added a second CT750 to its operations to

accommodate business growth.

Thomas said the programming software has proven easy to use, both for employees who are familiar with computers and those who are not. However, he pointed out that the best results require a combination of computer savvy meshed with familiarity with the grinding process.

Thomas Wire Die soon found that the shop had enough work to keep the STUDER grinder going nonstop. As a result, the company recently added a second CT750 machine. “The machine’s increased efficiency has freed personnel to move to other areas,” Thomas said. “Where we might have had three people doing work, now we have one and a half. The other one and a half are working in other areas because of growth we are seeing in other products.”

In addition to increasing revenue, expanding and diversifying a company’s customer base can help moderate the effect of economic slowdowns. “Part of our thought process in how we grew our business was to try to expand into different markets,” Thomas said. “Working with customers in wire and cable, oil and gas, metal forming, metal stamping and wear parts helped us historically in that when there was a downturn in one area it didn’t affect everything.”

The depth of the most recent “Great Recession,” however, certainly had more impact than past slowdowns. Thomas Wire Die reluctantly performed the first layoffs in the company’s history. “That was a culture change,” Thomas said. “We realized we had to look more closely at cost control. New CNC grinders and wire EDM equipment have allowed us to increase our output. We are also looking at ways to increase the utilization of the equipment we have. We run a single shift

now and we have a lot of capital equipment that sits idle two out of three shifts every day. We are looking at changing that, which will mean adding additional people.”

Today, Thomas Wire Die has 20 employees at its 17,000 sq ft. facility and handles between 150 and 200 accounts a year. The shop’s diverse skills enable it to participate in a variety of industry segments. For example, its cold-heading dies are used by suppliers to make fasteners for the aerospace industry. Similarly, the shop makes tooling that tier 1 and 2 suppliers use to deep draw and stamp automotive components.

The fastest growing market for wear resistant parts is the oil and gas industry. “There is more and more fracking activity in North America and worldwide, and it is driving a lot of that growth,” Thomas said. The shop makes carbide valve components up to 4" and 5" in diameter and 10" long as well as other parts such as nozzles and small wear rings. Some of the customers for the parts are international OEMs that use the components in assemblies that are shipped worldwide.

In the present era of struggling digital startups with alleged vast potential but questionable experience, Thomas Wire Die bases its growth on its prior successes and strengths, and applies that expertise to realize the potential of new and growing markets for its singular products and services.

Learn morewww.canadianmetalworking.com


Osborn’s Life

Product Engineer Enjoys New Experiences at Work and in Life

A G L I M P S E I N T O

y quest for adventure started early. As a kid, I built and raced go-karts with my family and friends. I have hiked many parts of the Appalachian Trail, backpacked in the desert out West and been paragliding and skydiving several times. In fact, I enjoy almost

anything outdoors. I ski and drive snowmobiles in the winter, and when the weather is warm, I play soccer, boat and do all sorts of water sports on the Saint Lawrence River. Most recently, I began participating in outdoor mud runs such as Tough Mudder and Spartan races.

I think my love of trying new things makes me a perfect fit for my job as a product engineer for United Grinding North America, Inc., especially since I am in the internal cylindrical grinding division. While the company has several well-established grinding departments, the internal cylindrical grinding division is fairly new. With a rapidly expanding product line and growing demand for the process in aerospace and automotive manufacturing, there are a lot of opportunities to grow this segment of our business — a challenge I gladly accept.

While the other grinding divisions have several engineers, I am the only one that is dedicated to internal grinding. This has given me a chance to learn all aspects of the business. I am able to work with customers to increase their understanding of internal grinding technology, support the sales team in quote creation, develop solutions for complex manufacturing cells and perform customer demonstrations, runoffs and applications tests.

I am also well suited for this job because of my past experiences. While studying mechanical engineering at Miami University in Oxford, Ohio, I gained an advanced working knowledge of welding, CNC machine tools, CNC programming and a slew of other technical skills. I also served as an engineering lab assistant where I mentored other students in the use of the university’s machine shop and designed and fabricated equipment for professors and the lab. One of my favorite school activities allowed me to put my early go-kart building skills back to good use. I was the suspension team leader for Miami University’s SAE Baja Team that designed and fabricated off-road Baja vehicles for intercollegiate competitions.

In my first job after college, I designed and produced automotive ball joints, tie rods and control arms for aftermarket customers. I handled the entire design and engineering process from start to finish for this new product program.

I am really focused on helping UNITED GRINDING grow its internal cylindrical grinding business. Although I have only been here a year, I am excited to be part of this team, and honored to have been nominated by my company and named to Manufacturing Engineering’s second annual “30 Under 30” Awards program.


n 1994, the 5-axis grinding machine HELITRONIC POWER revolutionized the way operators ground tools.

Over the past 20 years, this universal CNC tool-grinding machine from Walter Maschinenbau GmbH has proven to be one of the most successful machine

concepts in tool grinding and has revolutionized the way manufacturers think about grinding technology.

Job shops were looking to grind multiple applications using one machine at the time when WALTER introduced the HELITRONIC POWER. It was the company’s first machine capable of grinding almost all tools from carbide drills to end mills for both the metalworking and woodworking industries.

A special feature of the innovative tool-grinding machine was — and continues to be — its special axis kinematic assembly with a rotating axis workpiece holder. WALTER further advanced the machine’s design with transparent doors and rounded housing, which made the working area fully visible and accessible in an ergonomic way.

Today, a stable portal moves the machine’s grinding spindle in three linear axes. This capability not only provides easy access when changing grinding wheels and tools, it allows for a direct view of the grinding process and optimizes machine stiffness.

Up to six grinding wheels can now be mounted on the two ends of the grinding spindle for the complete machining of complex tool geometries. For automatic tool measurement and positioning in the machine, a 3D probe is firmly attached to the grinding head.

By 1995, these outstanding features spurred over 100 leading tool-grinding companies worldwide to choose the HELITRONIC POWER’s highly advanced and patented concept as their new way to grind tools.

A Rise to Power The 20-Year History of the HELITRONIC POWER

World Premiere at IMTS 1994Featuring a unique structure and kinematics,

the 5-axis HELITRONIC POWER with an HMC 400 CNC control revolutionizes

grinding tool technology.

F E A T U R E

The HELITRONIC POWER’s Route to Success

1994 1997HMC 500 Control

The new HMC 500 CNC control uses a standard built-in modem for remote diagnostics from the WALTER Diagnostic Center, providing users with

a new level of operating convenience.

1997HELITRONIC MINI POWER

Further expanding the HELITRONIC POWER’s innovative machine design, WALTER offers the

same technology in new sizes, including the compact HELITRONIC MINI POWER design.

2003HELITRONIC VISION

The WALTER HELITRONIC VISION, a high-precision grinding machine

alternative, is released.

2001HELITRONIC POWER DIAMOND

WALTER introduces the 2-in-1 HELITRONIC POWER DIAMOND,

the world’s first machine to combine grinding and EDM.

HELITRONIC TOOL STUDIO Grinding SoftwareWALTER unveils HELITRONIC TOOL STUDIO, its custom, in-house CAD/CAM grinding software,

which further simplifies programming for all parts.

2003Wheel-Changer TechnologyOperators are introduced to new

wheel-changing technology, which allows them to perform long periods of

unmanned grinding.

2006FANUC Control Technology

WALTER takes its tool-grinding control technology to the next level by

adding FANUC controls to all its machines.

2007Robot Loader

All machines in the HELITRONIC family are offered with an optional fully automated robot

loader, which loads up to 3,500 blanks and tools unmanned.

2010


“HAVE YOU PURCHASED THE BEST GRINDING MACHINE, GRINDING WHEEL, FILTRATION SYSTEM, AND COOLANT, BUT NOT GETTING THE RESULTS YOU EXPECT? THE PROBLEM COULD BE NON-OPTIMIZED COOLANT APPLICATION. DR. COOL CAN HELP YOU OPTIMIZE YOUR NOZZLES AND FLOW CONDITIONS TO

GET THE RESULTS YOU EXPECTED .”

OPTIMIZATION OF YOUR COOLANT APPLICATION WILL LEAD TO:• Reduction or elimination of grinding burn, with higher throughput.• Less wheel truing and dressing, giving longer wheel life.• Reduced coolant flowrate reduces electrical energy, filter size, and coolant disposal costs.• Better surface finish and process stability.

LEVELS OF GRINDING SUPPORT INCLUDES:• Auditing of existing coolant application, such as plumbing, nozzles, pumps, filters, and recommendations how to improve, through a 1 or 2 day visit.• Design and build of custom nozzle systems for OEMs and end-users.• Supply of specific and generic nozzle hardware for you to install.

visit COOL-GRIND.COM for more detailsCOOL-GRIND TECHNOLOGIES

32 Nott Highway, Ashford, CT 06278 [email protected] 1 (860) 429 8822 1 (860) 819 3259

John Webster PhD

With a graphical user interface, the HMC 400 CNC control further contributed to the HELITRONIC POWER’s early success. Operators were able to use three software packages to grind cylindrical and conical rotationally symmetrical tools. The machine also featured a software package specifically designed for woodworking tools. Parameter input via dialog boxes in “clear text” considerably simplified the programming of even the most difficult tool geometries. Intelligent and flexible software provided operators with much needed support for these challenging parts. This was the case for cylindrical and conical spiral cutters, step drills and general step tools, disc cutters, woodworking tools and taps.

A geometrical and technological database was then integrated, which provided users with a variety of field-tested data. Plus, over the years, additional software

packages were developed to extend the capabilities of the 5-axis tool-grinding machine. This ensured maximum flexibility and provided the grinding of complex tools with exceptional geometry up to the batch size 1, with a hitherto unbeatable attractive price-performance ratio.

In 1997, the HMC 500 CNC control was introduced, which offered a whole new level of operating convenience, based on the developments in computer technology in those days. For the first time, a tool-grinding machine was equipped with a digital control and PC-based drive system. A standard built-in modem permitted worldwide remote diagnostics from the WALTER Diagnostic Center.

During the following five years, WALTER utilized the new HELITRONIC POWER machine design concept and technology to produce similar machines in various sizes.

For example, the HELITRONIC MINI POWER was released in 1997 and the HELITRONIC POWER DIAMOND in 2001, which was introduced as the world’s first grinding and EDM machine. In 2003, the HELITRONIC VISION was introduced, which represented the most precise grinding machine in the WALTER product portfolio, with its linear drives and mineral cast bed.

WALTER also began offering the HELITRONIC TOOL STUDIO in 2003. This CAD/CAM software was developed in-house to be used on the entire series of HELITRONIC machines. It is independent from the kinematics and specially designed for the production of cutting tools for the metalworking and woodworking industries. Even complex tool geometries can be created quickly and easily. With the introduction of this software, WALTER once again proved its leading position in tool-grinding technology.

In order to further increase productivity and flexibility, WALTER presented a grinding wheel changer in 2006. Now, the 5-axis grinding machines can grind a wide variety of tools over a longer period of time unattended.

In 2007, WALTER started to use FANUC controls for its entire line of tool-grinding machines. These CNC controls are very reliable and provide all the technical features needed for

5-axis grinding machines. In addition, FANUC’s competence and fast service paired with a worldwide presence helped it support WALTER machines located worldwide. This dovetails perfectly to the customer orientation of WALTER and its global network of sales and service offices.

For maximum productivity in the mass production of tools, WALTER introduced its robot loader for the HELITRONIC POWER and other grinding machines in 2010. Offered as an option, the industrial robot loads and unloads several pallets in an unmanned operation with up to 3,500 blanks and tools, dependent on the tool and tool diameter.

This year, the HELITRONIC POWER celebrates its 20th anniversary. By listening to customers and understanding their needs, WALTER’s innovative new developments have created one of the world’s best-selling CNC tool-grinding machines. With the original HELITRONIC POWER sold in 1994 still in use everyday, through the 3,300 machines sold since, it is apparent that the POWER of this machine will see another landmark. Only time will be able to define the next innovation for the HELITRONIC POWER.

Learn morewww.grinding.com

20th AnniversaryWith more than 3,300 HELITRONIC POWER

machines sold worldwide, WALTER celebrates 20 years of success by creating a one-of-a-kind, custom-painted version of the classic HELITRONIC POWER machine.

2014

20 GQ/Job Shops Issue 2014

grinding setup times by as much as 50 percent. The machine’s laser scanner makes measuring easier, faster and more comfortable by creating a 3D model of the complete tool, which users can process and automatically evaluate.

5. NEW EWAMATIC Linear As a universal tool-grinding machine, the EWAMATIC

Linear delivers processing flexibility for the production of indexable inserts and rotationally symmetrical tools. The grinder’s new 6-axis design with direct drives in all three linear axes provides faster rapid traverse speeds, while an automatic clamping system delivers complete, precise machining in single clampings. The machine also features six independent grinding spindles, each of which can be equipped with two wheels.

6. HELITRONIC 30NC LIP2 First introduced in 1953, the WALTER HELITRONIC 30NC

LIP2 continues as the industry’s leading fully automated tool-grinding system. The historic grinder is one of the first NC-controlled machines on the market, and features 4-axis capabilities for increased processing versatility.

7. NEW HELITRONIC VISION 400 with wheel changer and robot loader

The WALTER HELITRONIC VISION 400 high-performance tool-grinding machine with wheel changer and robot loader provides maximum productivity and precision for grinding rotationally symmetrical tools from 0.12" to 12" in diameter and up to 14" in length. Designed for high-production environments, the machine’s grinding wheel changer couples with a 6-axis CNC robot to enable fully automated multi-shift unattended operation.

F E A T U R E


TOOL AND MEASUREMENT

1. HELISCALE The WALTER HELISCALE optical measuring device

provides precise testing and inspection of rotationally symmetrical tools up to 2" in diameter. An alternating V-block design allows for measurement from all angles, including outer diameter and end face. The HELISCALE can be used for in-process length, angle and radius measuring as well as during regrinding.

2. HELISET UNO The WALTER HELISET UNO is a compact, manual

measurement system that helps manufacturers reduce downtime. With an intuitive user interface, the HELISET UNO provides quick, simple and precise offline pre-adjustment of grinding wheels and tools.

3. NEW HELICHECK PLUS with robot loader As a fully automated 4-axis machine, the WALTER

HELICHECK PLUS provides complete measurement of tools up to 8" in diameter and 12" long. Featuring an extremely stable construction and a repeatability of ±0.00004", the machine is ideal for the measurement of high tolerance tools — such as high form tolerance and PCD cutters — and those with complex geometries. When equipped with a robot loader, users can measure and log up to 4,000 tools unattended. The machine is also available with optional automatic ultrasonic tool cleaning and laser marking capabilities.

4. NEW HELICHECK 3D The HELICHECK 3D is the latest in advanced optical

CNC measuring technology from WALTER. This 4-axis machine provides non-contact complete measurement with a repeatability accuracy of ±0.00004" for rotationally symmetrical precision tools with complex geometries. Ideal for in-process quality control, the HELICHECK 3D also provides measurement of production components like grinding wheels and diamond dressing rolls. The system’s fully automated functionality helps reduce

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United GrindingIMTS 2014 80’x100’1 story 06.29.14


Historic Machines

New Machines

New Technology


8. NEW HELITRONIC ESSENTIAL The WALTER 5-axis CNC HELITRONIC ESSENTIAL

tool-grinding machine excels in the regrinding and production of rotationally symmetrical tools and components from 0.04" to 4" in diameter and up to 10" long.

9. NEW LASER LINE ULTRA The EWAG LASER LINE ULTRA is a next-generation

high-end laser production center. With picosecond laser technology, the LASER LINE ULTRA makes easy work of rotating and insert tools made from superhard materials. The machine features a 5-axis machine kinematic system with superimposed 3-axis laser beam guidance for both laser machining as well as laser ablation.

10. NEW HELITRONIC POWER DIAMOND with wheel changer and HSK loader

As a two-in-one machine, the WALTER HELITRONIC POWER DIAMOND equipped with a wheel changer and HSK loader quickly switches from grinding of HSS/carbide tools to rotary eroding of CBN/PCD tools. The HSK loader and 6-position electrode/grinding wheel changer (3-position for motor spindle option) give the HELITRONIC POWER DIAMOND the agility to handle applications demanding frequently changing tools or long series of parts.

11. HELITRONIC POWER This custom-painted — in celebration of being the company’s

best-selling tool-grinding machine for the past 20 years — classic WALTER HELITRONIC POWER produces and re-sharpens rotationally symmetrical tools and complex parts with diameters from 0.12" to 12.6" and up to 14" long. The one-of-kind machine is equipped with a GE FANUC control, TOOL STUDIO software program and drive system.

SURFACE AND PROFILE

12. NEW MFP 100 The highly productive, flexible MÄGERLE MFP 100

profile grinding system provides fully automatic complete multi-face machining of complex and heavy parts. The machine features a unique dual gripper wheel-diamond

roll and automatic tool changer that expands up to 60 stations. The machine provides multi-tasking production with the integration of continuous-dress creep-feed grinding, CBN or conventional grinding, and milling, drilling and tapping processes.

13. PROFIMAT MC The BLOHM PROFIMAT MC employs the latest in

custom grinding technology with flexible solutions for various grinding applications. The moving column (MC) design allows for a variety of machine configurations including 3, 4, 5 or 6-axis CNC machine arrangements in a compact size (95" W x 170" D). The PROFIMAT MC comes in a variety of wheel dressing options including overhead continuous or table dress, and when combined with its CNC contouring capability, the machine meets the unique demands of precision grinding. The machine’s custom stainless steel enclosure and 5-axis CBN configuration provide the perfect solution for complex aerospace parts.

CYLINDRICAL

14. CT960 The STUDER CT960 universal internal cylindrical

grinding machine provides a flexible and compact solution for internal, external and radius grinding of small to medium-sized workpieces. Featuring a 4-position high-frequency spindle turret, integrated swivel axis and interpolating B-axis, the CT960 allows for complete part machining in single clampings. The machine’s durable design gives it exceptional strength for processing complex workpieces made from very hard materials such as tungsten carbide, ceramic and sapphire.

15. NEW S141 The STUDER S141 universal ID grinding machine is the first

in a series of new machines from UNITED GRINDING. In addition to the grinding of short workpieces, the addition of a steady-rest with a 16" swing allows for processing of workpieces up to 27" long. The S141 also features an automatically swiveling workpiece table for axis-parallel grinding and accessing up to four grinding spindles.

16. NEW S11 As the smallest machine in the STUDER portfolio, the

S11 cylindrical grinding machine provides precision, productivity and operational flexibility in just 71 in2 of floor space. The S11 offers excellent vibration dampening and thermal stability thanks to its patented Granitan® S102 base, and a high-speed grinding option provides peripheral speeds of up to 28,000 ft/min.

17. S41 The STUDER S41 universal cylindrical grinding machine

is a flexible, high precision machine for large batch production. Featuring four grinding wheels with more than 30 basic variations, the S41 provides external, internal and face grinding in single part clampings. A 21.6" swing and maximum distance between centers of 63" makes this the ideal machine for grinding larger, complex workpieces.

18. MIKROSA Centerless Grinding Machine Since 1949, MIKROSA has set the global standard in

precision centerless external cylindrical grinding machines. Today, MIKROSA Centerless Grinding machines feature a modular design for highly productive, high-performance throughfeed and infeed grinding applications.

19. NEW S33 with multiControl The versatile STUDER S33 cylindrical grinding machine

performs ID, OD and thread grinding operations on medium-sized workpieces in individual batch production. The machine’s universal workhead design allows the S33 to perform either live spindle grinding or grinding between centers. Equipped with a new turret wheelhead with two motor spindles and an internal grinding attachment, the machine lets users process complex geometries in single clampings. Available only on the S33, STUDER’s new post-process multiControl system provides absolute measurement of diameters and lengths while workpieces remain on the machine.

20. NEW STUDER-WireDress®

The latest innovation in grinding wheel dressing technology, the new STUDER-WireDress® System provides on-machine and in-process dressing for metal-bonded cylindrical grinding wheels. Featuring a more open structure, higher grain protrusion and less friction, the new STUDER-WireDress®

System offers better cooling and lubricating efficiency, lower grinding forces, less wheel wear and better dressing accuracy than conventional dressing methods.

Specialist for CNC rotary tables

General importer for North America

Rotec Tools Ltd.5 Schuman Road, Millwood, NY 10546

Phone: (914) 941-7311Fax: (914) 941-0226

Email: [email protected]

Wanted: local representatives

New generation 500:• Modular design: 4 basic modules – over 170 variations• Up to 111 min-1 – clamp and release quickly – short cycle time• High degree of accuracy: concentricity, geometry and positioning • Compact and rigid construction – high spindle clamping torque• Fully impervious to IP67 as standard – IP68 optional (waterproof in bath)• Large workpiece clamp range• Competitive prices

Rotec Tools Ltd.

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anufacturing has always been tough. These days, global competition, constant customer demands to make products better/faster/cheaper and a shortage of both skilled labor and engineering expertise are making it even tougher.

The brain drain of experienced machinists and engineers in particular has created opportunities for manufacturing technology suppliers such as UNITED GRINDING, based in Miamisburg, Ohio, to step in and fill the void.

By Larry Marchand,

Vice President of Sales,

Surface & Profile Division,


More and more customers are asking OEMs to do the manufacturing engineering for new products or processes, which historically they have done on their own. In manufacturing, we’ve seen an entire generation retire that grew up working with their hands. While on the technical side, they may have young engineers who lack proficiency in process development, or a customer may not have any engineering capability at all. So members of the UNITED GRINDING team have been assisting customers with everything from development of the machining concept to tooling, workholding, CNC programming — all the way to the final grinding and process development.

The UNITED GRINDING Profile Division’s applications engineering team can more than make up for the limited hands-on experience and engineering capability at many customer companies. Consisting of a manager and five engineers, the team has cumulative experience of 138 years — an average of 23 years per team member.

We’ve found it especially helpful to divide our application engineers into product teams, so they can become true specialists. We have two engineers who are heavily involved in aerospace, and two more who specialize in mold and die work. This structure allows these individuals to become experts within their respective industries.

Our applications engineers and other UNITED GRINDING personnel can provide support at whatever level a customer requires — from process development and programming to a complete turnkey package consisting of machines, process development and verification, training and technical on-site support.

In the specialty tooling industry, for example, we’ve had 50-person shops come to us in need of help with expansion into new markets. In this situation, they acquire the process from us. We train them on how to do the first job, and they take it from there for future jobs.

Today’s aerospace industry illustrates this type of expansion. Suppliers of aircraft engine components, for instance, have production operations in several areas of the world, and some of those areas may fall short when it comes to required knowledge base and infrastructure. For those companies, UNITED GRINDING can provide turnkey production grinding capability that includes machines, process development, quality assurance, programming, training and months — or even years — of on-site maintenance and support.

One particular example is a customer that required assistance getting a regional plant up and running. The customer contracted us to develop a complete startup for them, including all the


Partners in Grinding Productivity

F E A T U R E

S U R F A C E & P R O F I L E P R O D U C T T E A M S

2 aerospace engineers + 2 mold & die engineers

S U R F A C E & P R O F I L E D I V I S I O N A P P L I C A T I O N S E N G I N E E R I N G T E A M

1 manager + 5 engineers = 138 years combined experience

C O M P L E T E T U R N K E Y S O L U T I O N

process development + machines + programming + verification + training + support


machines, a grinding process, tooling and workholding to meet a very aggressive cycle time, as well as on-site operator training. The entire implementation process took two years. We even hired our own engineer in the region who worked on-site to support and service the machines with no language barrier. A more typical technical partnership might last only three to six months.

While about 70 percent of UNITED GRINDING’s Profile Division business revolves around either aerospace or land-based turbine component production, customers also produce tooling and components for many other applications, including hydraulic systems and medical devices. In one project involving a supplier of hydraulic pump components for the agriculture industry, we developed a fully automated system for the company to grind internal components of a hydraulic pump.

In the medical device industry, doctors are typically involved in new product development. They will meticulously develop a few prototypes, and if the prototypes seem to have promise, they create a production system. We helped a customer develop a grinding process to produce a carbon fiber heart valve. We created the process and tooling, then built a machine and produced several thousand parts.

After waiting several years for the U.S. Food and Drug Administration to test and approve the new component, the customer started production and purchased a second machine. That case was very unique — both the work material and part geometry were challenging. They were very small parts, much smaller than you would normally produce on the machine we supplied, but it was our ability to produce the required geometry that led the customer to UNITED GRINDING.

Application support also includes integration of process automation, inspection capability or even custom wheel development. The automation business has grown steadily the past three or four years. At UNITED GRINDING, we work with a variety of automation suppliers — either our own or customer-recommended integrators — to interface the robotic material handling system with our grinding process. We’ve also integrated in-process gaging and other capabilities such as parts cleaning. Now when parts come in, they are ground, cleaned, measured and go back out using a process we created.

Partnering to help customers implement solutions to specific grinding challenges can also impact UNITED GRINDING’s overall machine technology offering. An example of how

In addition to machines and other equipment, process development and application support includes determining applicable grinding wheel technology. However, when more than an off-the-shelf solution is needed, support partnerships with OEMs like UNITED GRINDING must expand, adapt and provide. Such was the case when UNITED GRINDING’s SchaudtMikrosa partnered with a grinding wheel supplier to develop a new unique wheel product for a customer.

After a thorough evaluation of the application requirements, SchaudtMikrosa first selected the correct machine for the job — in this case, the SCHAUDT CamGrind S. A compact machine aimed at production of smaller camshafts and similar components, the OD grinder can handle parts up to 25.6" between centers and uses cubic boron nitride wheels up to 19" in diameter. Other machine features include fast programming, hydrostatic guideways on the X-axis and a Granitan® base that reduces vibration during grinding. The CamGrind S also allows easy integration of automation, in-process gaging and other technologies for lights-out production.

Working with wheel supplier TYROLIT, engineers developed a wheel design with the CBN elements glued to a carbon fiber wheel body. Based on TYROLIT’s Genis CF wheel, the development cut floor-to-floor time by half compared with the previous process. It also minimized dressing — so much so that wheel life reached a full year in a three-shift manufacturing environment.

The wheel’s composite core provides multiple benefits over comparable wheels with steel cores. It weighs 80 percent less and can be replated multiple times if desired. The composite core provides excellent vibration damping to reduce chatter and improve roundness. Its lower weight also allows simultaneous performance of multiple grinding operations in a single step to reduce machining time.

PARTNERS EXTEND TO WHEEL TECHNOLOGY

Members of the UNITED GRINDING team have been assisting customers with everything from development of the machining concept to tooling, workholding, CNC programming — all the way to the final grinding and process development.

technology developed for one customer can trickle down to the product line is the case of a customer that was using a very corrosive coolant for grinding its parts. Over time, the coolant peeled the paint off the insides of the machine's enclosures. Because the coolant was a requirement for producing the customer’s particular types of parts, the only remedy was to use stainless steel machine enclosures.

As the trend toward technology partnerships strengthens, we will continue to provide not just grinding technology but also turnkey application support. We provide a single point of contact to manage the whole project. Regardless of the level of support required, we put the resources needed into each project to get it done in a timely manner. We typically have the expertise within our group, but if need be, we can draw on our European brand companies for help, because when it comes to making a process accurate, precise and repeatable, the devil really is in the details. We have the experience and skill set to take on that task and deliver the best solution for a particular grinding challenge.

Learn more www.grinding.com


amen Carbide Tool Co. Inc. in Wood Dale, Illinois, combines a passion for grinding excellence, vast amounts of experience and advanced CNC technology to create a culture that has allowed it to flourish for more than 65 years. The family-owned shop supplies

standard and custom carbide cutting tools and wear parts, and its second-generation President John Bachmeier has been hanging around the shop since he was five years old.

Bachmeier first watched his father run the shop. Then, he joined the company in 1979 and began to develop his own love and knowledge of grinding and Damen’s business niche. Now, Bachmeier is proud that a third generation of his family is working to keep the passion for grinding alive and producing quality carbide tooling and wear components.

Damen has a broad customer base, producing parts for electronics, medical, housing, oil and gas, mining, transportation, aerospace, military and medical applications, to name just a few. Whatever the industry, “basically everything we do is special — high-end, close-tolerance work,” explained Bachmeier. “The company started in 1948, and it has always been that way. It’s hard, but I grew up in it. That’s why I love it so much: it’s my life, my hobby. I’m just like my Dad — I like the intricacy and the accuracy, and I like seeing the technology advance.”

Advancements in grinding technology seem to be an especially potent driver of Bachmeier’s passion — and of the shop’s success. “When my Dad started, everything was manual,” he said. “But we bought our first CNC grinder in 1983, and we haven’t looked back.”

Since that first CNC machine purchase — a STUDER S40 capable of OD/ID grinding of parts up to 63 inches between centers — the shop has amassed an impressive collection of CNC grinders for cylindrical OD/ID, creep-feed, peel,

tool and surface grinding applications. All the machines have been brands now under the umbrella of UNITED GRINDING North America, and include STUDER, BLOHM and WALTER.

Damen’s first STUDER S40 featured all the bells and whistles, including wheel-indexing capability. The shop soon realized the machine’s flexibility and ease of programming, and it was quickly followed by two more S40s with the capacity to grind parts up to 40" between centers. Then came a STUDER S31 universal cylindrical grinder, followed by a STUDER S22 machine that was the first in the United States capable of peel grinding, Bachmeier said proudly.

Peel grinding uses a narrow wheel for efficient grinding of complex, small features in hard workpiece materials. The S22 can handle parts up to 31.5" between centers and features linear motor axis drives and a high-speed grinding option that allows circumferential speeds up to 27,600 fps.

Midwest shop introduces

advanced ID/OD grinding

technology to grow business.

F E A T U R E

Shop Propagates a Passion for Grinding


The common drivers of all Damen’s CNC grinding machine acquisitions are added production flexibility and processing capability. Bachmeier is constantly looking for ways to improve existing jobs and enable the shop to go after a broader range of work.

“We look for new equipment that will allow us to handle jobs we couldn’t tackle before and to improve upon existing ones, to open up the field,” he explained. “Our newest UNITED GRINDING machine is going to open doors for ID grinding jobs that were tough to win with only jig grinding or EDM capabilities. You have to keep up with the technology and the quality. If we want to be the best grinding shop in the world, which we try to prove every day, we know we have to keep up with the latest technology advancements. We have to

Recently, two STUDER S33 OD/ID grinders joined the shop’s lineup. The universal cylindrical grinders sport a new control and wheelhead to enable grinding of complex workpiece geometries in single part clampings. The wheelhead features two motor spindles for external grinding and an internal grinding attachment.

The shop’s latest STUDER is a CT960 universal internal cylindrical grinding machine for ID and contour grinding. It is equipped with an interpolating B-axis that swivels to 91° and a four-spindle turret. The machine’s extreme versatility allows it to grind complex OD and ID geometries in single setups.

have the best, and right now the machines from UNITED GRINDING are proving they are the best.”

According to Bachmeier, Damen routinely performs ID grinding with tolerances of ±0.0001". And along with its high-performance grinding equipment, the shop is temperature controlled to help achieve those tolerances. He added that an open tolerance at Damen is ±0.0002".Having UNITED GRINDING’s area distributor, Integrated Machinery Systems, in nearby Itasca, Illinois, also helps. “They work with us, and they’re in very close touch with STUDER,” Bachmeier explained. “We work with them on process development, and they provide expert application support.”

In addition to grinding, the shop has wire and sinker EDM, milling and turning capabilities. “But, we’re probably 90 percent grinding,” Bachmeier said. “People come to us for grinding, not so much for machined parts. The biggest reason we do machining and turning is to make our own fixtures for grinding.”

Those fixtures are becoming more complicated along with the geometries Damen is grinding. But according to Bachmeier, complex fixturing is part of the art of grinding when a part has to be held without distorting it.

Besides cutting tools, carbide components

the shop produces include dies, bushings, molds

and wear parts for oil and gas applications.

Many require both OD and ID work, and

Damen performs ID grinding on diameters

from 0.0030" to 16".

We’ve got about 120 machines and 30 employees,” said Bachmeier.

“Some guys run three or four machines, or even more. Once a job

is programmed, our CNC machines run the entire cycle needed to

produce a part instead of running single operations. And the operators

know that once they push the button a part will run, for example, for

45 minutes. So they can go work on other jobs.

that of other senior seasoned employees. At the same time, Bachmeier sees the adoption of new technology as a key to the current and future success of the shop.

“My sister, Rita Olvera, vice president of Damen, and I both have all our sons working here,” he said. “They’re comfortable with computers and programming. CNC has actually kept them interested. The software and graphics of our grinders really make a difference in that regard. If you look at how the programming software has evolved from the ‘90s to now, the difference is amazing. The current graphics and 3D capability almost make it look live.”

While the latest grinding technology may provide the spark, what really fuels Bachmeier’s passion for his work is knowing that the parts Damen produces play critical roles in their final applications. “It’s a joy to find out what your product does out in the world,” he concluded.

Learn morewww.grinding.com

The shop’s passion for implementing the latest technology also extends to quality assurance. Damen uses a variety of in-process and post-process gauging equipment, including WALTER HELICHECK machines and high-end coordinate measuring machines, to maintain its customers’ tight dimensional and surface finish requirements.

As for automation, Damen has yet to try the automatic loading/unloading capability that’s available for its CNC grinders. The shop’s variable lot sizes — from one piece to hundreds — and many custom jobs limit the utility of automation for those functions.

“We’ve got about 120 machines and 30 employees,” said Bachmeier. “Some guys run three or four machines, or even more. Once a job is programmed, our CNC machines run the entire cycle needed to produce a part instead of running single operations. And the operators know that once they push the button a part will run, for example, for 45 minutes. So they can go work on other jobs.”

Business at Damen has steadily grown over the past couple of years, and Bachmeier attributes a large portion of that continued success to a deep knowledge of the grinding process that comes from his own experience, as well as


While the latest grinding technology

may provide the spark, what really fuels

Bachmeier’s passion for his work is knowing

that the parts Damen produces play critical

roles in their final applications.

Although the shop does produce standard tools and wear parts from in-stock blanks, most of Damen’s work involves grinding of custom tools and wear parts. For custom parts, time from ordering of preforms to delivery is typically six to eight weeks.

“Deliveries on circular saws and knives, for instance, are faster, because we have more standard sizes of blanks,” Bachmeier said. “But most of the preforms for OD/ID and flat grinding have to be ordered. Basically, we have no standard items.”

Besides cutting tools, carbide components the shop produces include dies, bushings, molds and wear parts for oil and gas applications. Many require both OD and ID work, and Damen performs ID grinding on diameters from 0.0030" to 16". And, a large majority of those parts have holes that are used as datums with very close tolerances, so an out-of-tolerance hole could lead to a scrapped part.

Damen’s emphasis on grinding carbide and other hard materials means the shop uses a lot of diamond grinding wheels, minimizing the need for wheel dressing. “The forms we need are usually on the wheel already, and of course the diamond doesn’t need dressing,” Bachmeier said.

SCAN THE CODE

TO LEARN MORE

By Rob Bunting, Czar

Cincinnati I-marketing Group

f you are responsible for a business website and tracking its performance, you probably know that the top three U.S. search engines — Google, Bing and Yahoo! — drive a significant amount of the traffic to that website.

It is therefore very important to maximize the visibility of your website’s listings in Internet search results through Search Engine Optimization (SEO).

For years, the most common way for online marketers to improve SEO was to select frequently searched keywords related to a client’s business, and insert them into the existing website page content, along with page titles, META descriptions


and keyword tags that search engine crawlers analyze. The idea was that incorporating popular keywords would drive more people to the website and allow it to achieve higher search engine rankings.

In the late ‘90s and early 2000s, this process was very effective. In fact, it often worked too well, as poorly written, repetitive webpages stuffed with keywords would rank higher in search engines than pages with better content.

Over the past few years, however, the leading search engines — Google in particular — have altered their algorithms to help prevent keyword-stuffed pages from showing up in their top results. Instead, these search engines now favor well-written, helpful content that meets the searchers’ needs.

Matt Cutts, the Google engineer who heads the team responsible for the quality of Google’s search function, has stated that Google has ignored the keyword META tag for years. In fact, keyword tags are now considered a spam signal and can actually count against you.

So how can today’s business website owners evolve with Google, Yahoo! and Bing’s recent algorithm changes and implement an SEO effort that not only earns top search engine rankings for content but also turns website visitors into prospects and customers?

I recommend focusing on the searchers’ intents and determine where they are in the buying cycle. Then, write content that incorporates keywords targeted to your visitors’ needs. The goal is not to get as many people as possible to your site. Instead, you need to draw the right sales prospects to your site, provide them with information on how your products or services will solve their problem and get them to take the action needed to move them along in the “sales funnel.”

For example, consider the SEO strategy of a real estate agency in Topeka, Kansas that specializes in single-family homes. The agency could optimize their content for the term “Topeka real estate,” which gets searched frequently but is too general to reach a large share of the real estate agency’s target market. Instead, the agency could create a “Top-Rated School Districts in Topeka” page on their website and list homes from each district on that page. There will likely be fewer people searching for this specific information, but the content will be more relevant to the agency’s target market. Therefore, it is more likely to be classified higher-quality content by search engines and thus, rank well in search results.


O P T I M I Z E

How the Latest Search Algorithms

Are Impacting Your Website Presence

Once a business website’s SEO strategy is in place, the next step is to measure its effectiveness. This can be done by tracking the key performance indicators related to the underlying business and marketing goals. These include: revenue, catalog or product information downloads, newsletter sign-ups and the number of sales leads generated from search engine traffic. If you rank No. 1 in Google for a high-volume keyword, but that listing does not generate business for you, is it worth anything? In my opinion, the answer is no.

I recommend using Google Analytics or a similar program to track the performance of your website. You can sign up for a free Google Analytics account at analytics.google.com and have their tracking code added to every page of your site. Your Webmaster or website designer should be able to easily add Google Analytics.

Using Google Analytics, you can track the volume of site visitors you’re attracting from Google, Bing and Yahoo!, as well as other sources of traffic such as Facebook, Twitter or your email newsletters. And, you can track visitor activity on your site, such as page visits, email newsletter sign-ups, price list downloads or information request form completions. These are the things that really matter in determining the impact of your website and how effective your SEO efforts are over time.

Someone from your sales or marketing team, or an external advertising agency or marketing consultant, should regularly monitor these key performance metrics and communicate the results and recommendations for improvement to whomever is responsible for the website.

Appearing on the first page in Google for high-volume keywords is not a guarantee for success. However, if you select high-focus keywords that are closely related to your business, produce quality leads, track your key website performance metrics and keep an eye on trends and how changes to your website affect your results, you will be well on your way to having a successful SEO program.

Learn more Rob Bunting is Czar of the Cincinnati I-marketing Group, an Internet marketing agency in Ohio serving manufacturing, B2B and B2C clients. Learn more at CallTheCzar.com or contact Rob at 937-312-1400.

“Write content that incorporates keywords targeted to your visitors' needs.”


started his thorough investigations of grit wear based on the first principles of grinding chemistry, chip thickness and grit forces.

In addition to the work of these pioneers, to date, there have been thousands of published studies investigating wheel wear, grinding chemistries, chatter and thermal damage that transcend grinding into a science rather than an art form. We’ve also seen several OEMs develop intelligent software for their grinding machines, which makes the grinding process easier and more understandable for operators. However, on the shop floor, grinding is still often treated as an art form, with operators relying on past experience, trial and error and general “feel.”

Why is this shooting-from-the-hip approach still widely used? One reason is that most of the available scientific work is still trapped inside software algorithms and academic articles in a style that is all but incomprehensible to anybody without a Ph.D. The concept of grinding heat, for instance, is wrapped up in the mathematical concept of “cutting and sliding chip-formation energies in joules per cubic millimeter.” The rule of thumb that “you want the wheel RPM divided by the workpiece RPM to be a fractional number — like 9.12353" — and not an integer — like 9.00000" — is written as “the non-nodal frequencies occur at ωs/ωv ≠ IN, where N is an integer.”

Huh? Non-nodal? ωs/ωv? What?Even now, I go to trade shows and academic conferences such as IMTS, GrindTec, EMO and INTERTECH and listen to talks that are angled toward guys in real production — and the content there is also academic. People on the shop floor — smart guys, who have to deal with heat treatment, coating,

filtration, delivery times and company politics — are hoping for some nugget to take away with them. Often, they leave disappointed.

Over the past 10 years, I’ve spent thousands of hours “translating” high-quality work from academic speak into plain English. It’s not a quick or easy job. I find a good article and then spend 20 hours recreating the graphs and thinking how best to convey the information in an easy-to-understand format.

“Specific rubbing and chip-formation energies” is translated into “grinding heat,” “%∆zN/dg” is translated into “wheel-wear depth,” the cryptic formula “ωN/ωw” is translated into “wheel RPM divided by workpiece RPM.” The end result is something people can grasp, and they then say, “Ok. I see why we didn’t have chatter in the morning, but then it got horrible in the afternoon, and then disappeared in the evening. We had an ‘integer value’ as the wheel diameter got smaller.” When I present these concepts this way, I see a lot of “aha” expressions on people’s faces, especially those with lots of hands-on experience.

The Aha! MomentI teach grinding courses, and the people who attend them range from old-time machinists who want to add to their skills to completely “green” machine operators trying to learn even the basics of grinding, to experienced production supervisors wanting to add to their skills. But the ones I enjoy most are people who’ve worked in grinding for maybe 10 years — young enough to still be curious, but not too experienced to be set in their ways.

ntil the 1950s, grinding was something of an art form. Machine operators would mount a stone wheel onto some kind of machine tool, pick some speeds and feeds that sort of “felt right,” make some adjustments based on sound and general feel, and they were off

and grinding. They may not have been grinding well, but they were removing material. Over time, machine operators developed a feel for the machine and made adjustments accordingly. Grinding was part feel, part experience, part art, and part voodoo. Perhaps mostly voodoo.

In the 1950s, Leo Tarasov of Norton and Professor M.C. Shaw did the first serious scientific investigations into grinding, using machining chip-formation principles as a starting point. In the 1960s, De Beers’ Frank Hughes investigated how diamond grits behave when grinding hard materials. Then, Stephen Malkin

Dr. Jeffrey Badger, “The Grinding Doc”

Cutting Tool Engineering

F E A T U R E

of Grinding Knowledge

Back in Diderot’s day (1713 to 1784), grinding was part science, mostly art. Unfortunately, in spite of our much better understanding of the science of grinding, this is still the case in many grinding factories.

Attendees to The Grinding Doc’s three-day course in Hasle-Rüegsau, Switzerland, hosted by Blaser, worked on an assignment to calculate coolant exit velocity using The Ol’ Bucket-and-Stopwatch Technique.

Basic grinding formulas given in algebraic format and in simplified format.

4. SIMPLIFIED

2. SIMPLIFIED

1. ALGEBRAIC

3. ALGEBRAIC

Now I just present the facts and say, “What do you guys think?” Joe will speak up, and say, “How about a 150-Mesh wheel, and I can then dress the wheel sharp.” Joe takes ownership of the idea. And it works.

Slow and steady wins the raceI’ve had hundreds of people go through my courses and have visited grinding companies in over 30 countries. When I leave, I tell them: “Don’t try to revolutionize everything tomorrow. That’s a recipe for disaster. Slow and steady wins the race.”

I hear back from many of them. Those who are doing the best are the ones who analyze, measure, think, consult The Book of Grinding, think some more, make one change, measure again, think again, and then draw conclusions. It’s a slow process. But it’s the best process for making steady, significant, long-term improvements. Having an excellent grinding education, starting from the foundation and building from there, is the key to grinding success.

About the AuthorDr. Jeffrey Badger, known as “The Grinding Doc” from his question/answer column in Cutting Tool Engineering, is an expert in grinding who works as an independent expert and consultant, visiting companies around the world and assisting them in grinding. He will be giving his three-day High Intensity Grinding Course October 20-22 in Las Vegas and December 3-5 in Chicago.

Learn morewww.TheGrindingDoc.com

They’ve got just enough practical experience that when you tell them the “why” behind a concept, they just soak it up like a sponge. Concepts like, “I know when I slow down the feedrate in an attempt to reduce burn, the burn sometimes gets worse. It’s counterintuitive, but now, it all makes sense. My Aggressiveness Number is smaller, and I’m doing more rubbing. And, I’m spending more time in the hot zone. What I should really do is take a smaller cut and increase the feedrate, not decrease it.” Or, “Now, I see why when I increased only the feedrate I chewed up my diamond wheel, but when I also increased the wheel speed, I was ok. My chip load stayed the same.”

Teach a grinder to fish, and he fishes for a lifetimeMost of my work involves visiting companies doing the grinding and spending time on the shop floor. In the early days of my career, I would go into a company that was, say, suffering from grinding burn. I’d adjust the grinding and dressing speeds and feeds and maybe change the wheel specification. The burn would go away, and I’d leave.

Six months later I’d come back to the shop and what parameters were they running? The same parameters they had originally. I’d say, “What’s going on?” They’d say, “Yeah, your parameters eliminated the problem. But Joe’s been running that machine for 10 years, and he just sort of likes the way he does things. Your parameters work great, but we had to start grinding larger sizes and Joe just sort of drifted back to what he knows. And when you changed the parameters on

Joe, the ones he’s been using for 10 years, I think he kind of took it personally.”

Now I take a different approach. I analyze the process on the shop floor and then spend a day in the conference room with Joe and the engineers educating them on grinding fundamentals, dressing and cooling concepts. Next, I present to them how they’re doing it. I then step back and say, “So, what do you guys think? What’s going on? Why are we getting burn? What should we do?”

Once they understand the fundamental concepts, the solutions are pretty obvious. But instead of force-feeding it to them, I let them come up with the solutions themselves. By doing so, they take ownership of the science. I find this approach works much, much better. Now, next time they have the problem, perhaps on a bigger size, Joe the Grinder has the knowledge and tools to figure out the solution himself.

There’s one classic example I see all the time. A company experiences burn and chatter and has been battling it for years. The Book of Grinding recommends a grit size of 150-Mesh for the shop’s required surface finish, but they’re using 60-Mesh. Inevitably, when we analyze the dressing, we see that their diamond-traverse speed is incredibly low and their dressing depth of cut is light. They’re dulling the wheel during dressing to achieve surface finish. If I say, “Hey, you’re using the wrong grit size; get a finer-grit wheel and dress the wheel sharper,” I’ll be stepping on Joe the Grinder’s toes because he’s the one who came up with those parameters. In fact, somebody gave him the wrong tool for the job — a 60-Mesh wheel — and he somehow made it work. It didn’t work well, but it worked.


Highly complex grinding operations can often require the calculation of more than 300 machining parameters before the grinding wheel even touches the workpiece. This process places extreme pressure on machine operators and programmers tasked with setting up the production operations. These individuals must wade through a myriad of possible parameters to determine the right ones for the particular application at hand and do so quickly and without errors.

Fortunately, many of today’s grinders come equipped with intelligent software technology. These software packages take the guesswork out of determining proper grinding parameters and make the overall machine setup process considerably easier and faster.

Advanced integrated intelligent software, such as StuderTechnology within StuderGRIND and StuderWIN from UNITED GRINDING, places data from countless grinding tests and years of applications

Intelligent Software

Takes the Guesswork

Out of Grinding

expertise at the machine operator’s fingertips. This data is used to easily determine the best machining strategies for practically every grinding scenario.

StuderGRIND off-line programming software allows users to virtually recreate the components of the grinding machine and simulate the entire grinding process for more accurate, efficient setups and fewer errors. The software also stores crucial workpiece-oriented data.

The StuderWIN operating system provides simple dialogue guidance through several critical grinding functions, such as machine setup, tool definition and management, corrections, program creation, and process

visualization, to help users achieve efficient, cost-effective production.

As a complement, UNITED GRINDING also offers training courses for these software systems and other fundamental grinding topics.

In addition to setup reductions, intelligent software programs can help reduce overall machining times by as much as 50 percent. This is due to the fact that machine operators no longer have to devote huge chunks of time to first calculate then test machining parameters. And, being able to get parameters right as quickly as possible is especially beneficial when working in small-batch production environments.

Intelligent grinding software consistently ensures the optimal machining time at the press of a button. In addition, it helps reduce scrap, maximize efficiency and accuracy and ensures the best parts possible in the shortest amount of time. Without advanced technological solutions such as intelligent grinding software, shops run the risk of under utilizing their grinding wheels and prolonging part machining times.

SCAN TO FIND ATRAINING CLASS


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Optimize production of precision large, complex workpieces.

Multiple machining operations in a single clamping.

The MÄGERLE MFP 100 optimizes the production of precision large, complex workpieces by performing multiple machining operations in a single clamping.

At the core of the MFP 100 is the automatic tool changer (ATC) with a unique dual gripper that changes out grinding wheels and diamond rolls simultaneously. Utilizing a robust HSK-80 clamping system, the machine has standard capacity for 15 grinding wheel and diamond roll sets (30 pockets), with a 60-position ATC also available. To complement the machine’s multi-tasking capability, the ATC accommodates mills, drills and an IR machine probe to provide complete part machining.

The MFP 100 is available in 3 and 5-axis configurations and comes standard with an EROWA UPC 500 quick-change pallet system. A variety of other pallet systems will also pair with the machine.

Designed as a heavy-duty continuous-dressing creep-feed grinder, the MFP 100 achieves extremely high metal removal rates. It can also accommodate special grinding applications that require CBN or conventional grinding processes.

MÄGERLE MFP 100 Serves as Heavy-Duty Multi-Tasking Solution

The MFP 100 includes a 2-axis coolant nozzle system that quickly positions the nozzle to the optimum grinding position for each unique wheel size and shape.

The Siemens 840D Solution Line control that comes with the MFP 100 features a grinding-specific user interface for parametric programming. Through the control’s flexible and simple programming, it is easy to create a variety of grinding and dressing cycles for specific grinding applications.

As with all MÄGERLE grinding centers, the MFP 100’s unique wrap-around hydrostatic oil film guideways provide high thermal stability, smooth axis movement and vibration damping of the oil film to provide a fine, accurate grinding finish.

The extremely compact, highly versatile BLOHM PROFIMAT MC (95" W x 170" D) employs the latest in grinding technology to perform profile, internal or external cylindrical operations in countless applications.

A moving column (MC) design makes it possible for the machine to come in several different versions, including 3, 4, 5 or 6-axis CNC machine configurations. An optional vertical spindle configuration allows the PROFIMAT MC to perform ID/OD grinding and specialized gear applications, while an elective two-station index table maximizes production via simultaneous grinding and loading operations.

Grinding spindle drives with power up to 75 hp and maximum cutting speeds of 30,000 sfpm guarantee outstanding performance in any abrasive application.

Unique to the PROFIMAT MC is a wide variety of wheel dressing options, ranging from an overhead single or double dresser for continuous-dress grinding to table-mounted options up to 10" wide for conventional and CBN dressing to diamond discs for CNC profiling of the wheel shape.

BLOHM PROFIMAT MC Brings Grinding Versatility to Complex Part Production

The PROFIMAT MC comes with a Siemens 840D Solution Line control that features a grinding-specific user interface for parametric programming. Through the control’s flexible and simple programming, it is easy to create a variety of grinding and dressing cycles for specific grinding applications.

The optional 24-position automatic tool changer utilizes a robust HSK-80 clamping system for wheels up to 16" OD and an assortment of mills and drills for multi-tasking production.

Users can also take advantage of the PROFIMAT MC’s productivity enhancing accessories, including integrated inspection systems, automated part loading, and custom workholding solutions for a broad range of customer-specific solutions.

Suited for oil or water coolant, the PROFIMAT MC can operate with any abrasive combination to provide the highest productivity for a specific application.

Performs profile, internal or external

cylindrical operations in countless applications.

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STUDER S33 Facilitates Rapid Process Changeovers and Precision Cylindrical Grinding

STUDER favoritCNC universal internal and external cylindrical grinding machines provide a cost-effective way to achieve individual and batch production of medium-sized workpieces. A selection of features and options including in-process gauging, balancing, contact detection and length positioning systems enable the machines to be easily adapted for a variety of grinding applications.

The turret wheelhead can be equipped with an external grinding wheel and an internal grinding spindle to perform both external and internal grinding in one setup. Users can manually index (2.5°) the wheelhead in a Hirth gear within a swiveling range of -15° to +195°.

STUDER grinding software with StuderPictogramming enables users to quickly program grinding and dressing cycles. Optional StuderGRIND supports special applications, such as profiling grinding wheels for complex workpiece shapes, and permits creation of programs on an external computer. With distances between centers of 25.6" / 39.4" and a center height of 6.9", favoritCNC machines can grind workpieces with a maximum weight of 176 / 264 lbs.

The STUDER S33 CNC universal cylindrical grinding machine is designed for precise, highly productive individual and batch grinding of medium-sized workpieces. Fast changeovers between grinding processes is a key capability, as retooling from grinding between centers to live spindle grinding is achievable with the help of the STUDER Quick-Set software-controlled setup device.

A wheelhead with two motor spindles enables both grinding wheels to better utilize the entire table length, permitting grinding of complex workpieces in a single clamping. External and internal grinding are possible in one setup with an internal grinding attachment and an optional external wheelhead. A wide selection of other features and options enable machine performance to be tailored to individual production requirements.

The S33 machines are engineered to handle medium-sized workpieces, with distances between centers of 25.6" / 39.4", a center height of 6.9" and capacity for workpieces weighing as much as 176 / 264 lbs.

A cost-effective way to achieve individual and batch production

of medium-sized workpieces.

Designed for precise, highly productive individual and

batch grinding of medium-sized workpieces.

STUDER favoritCNC Universal Cylindrical Grinding Machines Are Precise, Flexible and Economical

F E AT U R E S A N D B E N E F I T S

• Rigid MT4 tailstock and MT5 workhead provide 0.000016" runout chucked or between centers

• Center pressure adjustment allows taper corrections less than 0.00004" when grinding between centers

• Virtually wear-proof knobbed ways ensure positioning accuracy and reduced slip-stick

• 20" diameter OD wheel provides more abrasive with easy changeover

• Rigid structure results in straightness of 0.0001" over 25.6" measuring length

• 12-hp OD spindle and cutting speed of up to 9,840 sfpm maximize metal removal rates

• Infinitely variable speed belt-driven internal grinding spindle

• Pneumatic lifting feature facilitates workhead movement

• Workhead roundness accuracy < 0.000016"

• Longitudinal (Z-axis) slide travel 31.5" / 45.3"

• Cross slide (X-axis) travel 11.2"


• User-friendly STUDER integrated grinding software comes standard and requires minimal grinding programming knowledge

• STUDER smartLoad add-on loader automates grinding of shaft components up to 11.8" long and 3.9" in diameter

• StuderPictogramming software allows users to quickly program grinding and dressing, and available StuderGRIND software enables efficient programming of special applications such as form and thread grinding

• Wheelhead drive power 10-hp / 12-hp external, 15-hp universal

• Roundness accuracy of better than 0.000016", optionally improved to under 0.000008"

• Taper corrections in the 1 micron range possible during live spindle operations

• Workhead and tailstock are equipped with pneumatic lifting devices to facilitate movement during setup and resetting

• Universal 1 to 1,500-rpm workheads have 2.2, 4 or 5.4 hp

• Optional 1 to 1,000-rpm, 2.96-hp chuck workhead expedites individual part production

• Grinding straightness of 0.0001" over 25.6" measured length

• Cross slide (X-axis) travel 11.2"

• Longitudinal slide (Z-axis) travel 31.5" / 45.3"

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New WALTER HELITRONIC VISION 400 Combines Automation with Precision

Provides maximum productivity and precision in automated mass production

of rotationally symmetrical tools.


• Internal measurement system for on-machine gauging

• Glass scales for linear axes confirm process accuracy

• Maximum workpiece length — peripheral grinding 14", end face grinding 10"

• X-axis 20", Y-axis 14", Z-axis 27.5"

• Rapid traverse speed of 591 ipm in X, Y and Z-axes

• C-axis rotation ± 200°, A-axis rotation ∞

• 750-rpm A-axis torque motor

• Linear resolution of 0.000004", radial resolution of 0.0001°

• Maximum workpiece weight 110 lbs.

• Peak power 24 kW

• Grinding spindle speed 0 to 10,500 rpm

• Maximum grinding wheel diameter 10"

Introduced at UNITED GRINDING’s 2014 Grinding Symposium, the WALTER HELITRONIC VISION 400 high-performance tool-grinding machine provides maximum productivity and precision in automated mass production of rotationally symmetrical tools. With six locations that can accommodate a total of 18 grinding wheels, the machine’s grinding wheel changer couples with a 6-axis CNC robot to enable automated multi-shift operation.

The HELITRONIC VISION 400 can grind tools from 0.12" to 12" in diameter and up to 14" in length, including milling cutters, hobs, drills, stepped drill bits, formed tools and woodworking tools made of HSS, hardmetal, cermet, ceramic and CBN.

The machine’s FANUC control unit and WALTER HELITRONIC TOOL STUDIO software efficiently manage grinding and auxiliary production process times. A rigid cast iron machine base with a patented portal design minimizes vibration to maximize grinding precision.

The EWAG LASER LINE ULTRA is a next generation high-end laser production center for superhard rotating and insert tools. Making its North American debut at IMTS 2014, the machine features a 5-axis kinematic system (X/Y/Z/B/C axes) with superimposed 3-axis laser beam guidance (U/V/W axes). This special design, allows the LASER LINE ULTRA to laser machine tool cutting edges as well as laser ablate cavities and complex chip breakers in single part clampings.

A 50-Watt high-power picosecond laser is integrated into the machine structure. The ultrashort pulse laser technology accomplishes direct vaporization of the material without significant heat generation. Coolant-free laser ablation applies to a wide range of superhard cutting materials, including monocrystalline diamond, chemical vapor deposited diamond, polycrystalline diamond, and polycrystalline cubic boron nitride and carbide. Laser control is fully integrated into the machine software. As standard, an integrated 6-axis articulated-arm FANUC 200iC robot with a triple gripper head provides fully automated part processing.

EWAG LASER LINE ULTRA Processes Superhard Tools With Advanced Laser Technology


• Integrated 3D measuring probe enables precise calibration of soldered-in diamond blanks

• C-axis toolholding fixture can be equipped with mechanical or vacuum clamping systems to accommodate plate-shaped tools

• Various tooling solutions permit processing of inserts and rotary tools

• Fully automatic interface available for HSK-63 rotating tools

• Integrated extraction unit removes flue gases

• Water-cooled direct drives cover an X/Y/Z traversing range of 16" x 7" x 6"

• Compact 16 ft2 mounting area

• LaserSoft software for laser machining applications

• Standard interface to STEP and IGES and most commonly used CAD systems

• Full 3D-modeling functionality enhances speed and accuracy

• Easy programming with new 3D CAD/CAM plug-in LaserPro 3D

A next generation high-end laser production center for superhard rotating

and insert tools.

L A S T T H O U G H T


t UNITED GRINDING North America Customer Care, we view every customer concern or request as an opportunity — one that either helps us solve a machine problem or improve our support initiatives overall.

To streamline the process of gathering customer feedback, we rolled out a “Voice of the Customer” initiative that utilizes the Net Promoter Score system. This system allows us to quickly gather customer feedback and analyze the data. Since its implementation, we have received extremely valuable feedback, especially from small to medium-sized shops. The feedback includes requests for additional helpline support, more field service technicians and a better spare parts inventory. In response, we are taking action.

By paying close attention to our customers, we are able to pinpoint developing issues and begin a root-cause analysis phase. Once we’ve identified an inefficiency, we work to ensure that we are continually improving our services and products. We gain a great sense of pride and accomplishment from interacting with our customers — whether it be receiving customer feedback, responding to concerns or implementing changes.

We understand that timeliness is a big concern for our customers. Therefore, we take steps every day to ensure we have the right parts in stock, enough direct helpline support and enough field service technicians in the right locations. With the resurgence of manufacturing in North America, no customer can afford to lose any productive capacity because of a down machine. Time is money, and once time is lost it cannot be remanufactured or brought back.

We continue to hear that there are about 600,000 manufacturing jobs currently unfilled because employers cannot find skilled workers. At UNITED GRINDING, we help our customers counteract this shortage by providing them with an experienced helpline team and hands-on field service technicians. Considering the high level of technology involved in today’s machine tools and the complexity of the processes they carry out, our team members must be grinding experts. Plus, with shortened production schedules, we must also be able to solve our customers’ issues faster than ever before.

We too are faced with the challenge of finding people who have the skills we need. And as an added requirement, our experts must be willing to travel somewhere new every week to solve customers’ issues in their facilities.

To develop and maintain the skills our people must have, our brand companies in Europe have set up training academies for field service technicians with fully documented curriculums and dedicated demonstration machines. These programs enable our newest technicians to become factory trained and move into the

By Joseph Szenay,

Vice President of Customer Care,



D I G I T A L D I G E S T

hen it comes to trade shows, there is a lot of strong content to be shared — products and technology on

display, event photos and presentation schedules, just to name a few. Here are seven helpful tips on how

you can use networks such as Facebook® and Twitter® to promote your booth and products, interact with

your audience and gain new followers.

Social Media Trade Shows

Follow the show’s social media accounts. This allows

you to easily monitor what content is being posted before

the show. And, you’re able to share and retweet relevant

information to your followers. Following relevant accounts

also allows you to tag and mention them in your posts,

which means your reach goes even further.

Use hashtags. Find out if the show is using any recurring

hashtags, and if so, begin incorporating them into your posts.

When you use relevant and common hashtags, users are

able to easily find your content. Go a step further and create

your own event hashtag so your followers can distinguish

what content is relevant to your show presence.

Post original content. Provide followers with sneak

previews of what products and technology will be at the

show by posting highlights prior to

the event. Continue these

posts during the show

to direct traffic to

your booth. Just

be sure to include

links back to

where followers

can find more

information.

Schedule basic content posts ahead of time. You can

use programs such as Facebook, Hootsuite® or TweetDeck®

to schedule posts in advance. This is a great way to send out

information to your followers when you’re busy on the show

floor. Just remember to always be mindful of the content

you’ve scheduled and be sure to update it when necessary.

Live tweet and post from the show. This is the

best way to share what’s going on at your booth with your

followers. Just don’t go overboard. Posting too much can

deter followers. And, make sure to include content that’s

interesting and dynamic. Photos are a great way to capture

a follower’s attention in a news feed or timeline and can be

easily taken with a smartphone camera.

Engage with your followers. The social media

community is abuzz during trade shows, use this as an

opportunity to like, comment, retweet and follow your fans.

This type of interaction increases your brand’s presence

online and creates rapport with your audience. If time

permits, follow the show’s hashtags or keywords to interact

with others even if they aren’t interacting with you.

Post event summaries. After the show is over, post

event highlights on your website and social media pages.

If you’ve taken pictures, create a Facebook album. Or,

if you receive online coverage from publications, share

them with your followers. This is a great way to continue

creating publicity.

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field faster than ever before. Such ongoing training is a global initiative for the UNITED GRINDING Group, and our customers are already seeing huge benefits from it.

Factory training enables our newest field service technicians to confidently provide expert help to our customers. And when our field technicians are armed with high levels of knowledge and skill, they are able to bring customers’ grinders back into production faster and thereby save time and money.

We also continue to offer a full range of training for our customers, either at their facilities or ours. Classes range from machine operation and applications training to machine maintenance and troubleshooting.

At UNITED GRINDING North America, we not only listen to our customers, we truly hear them. This has allowed us to look at our Customer Care organization in a new way. The Customer Care methods and staffing of the past can no longer support the demands of today and the future.

Over the last several years, we have made changes to our organization to help meet our customers’ ever-changing needs. One such example has been the growth of our field service department, but Customer Care isn’t just about field service technicians.

We’ve learned that many of our customers want us to be the one-stop shop for all of their needs. We are stepping up and accepting that challenge. More and more of our customers are asking us to go beyond simply servicing the equipment in their facilities. They are requesting more availability of helplines and remote diagnostics as well as more comprehensive upgrade, rebuilding, retrofitting and repurposing services for their machines.

As our customers look to maximize the productivity of their machine tools, we must meet their present needs as well as anticipate their future requirements. This way, UNITED GRINDING North America will continue to exceed our customers’ expectations and reinforce their competitiveness in the global manufacturing industry.

L A S T T H O U G H T continued

Others may try to “razzle dazzle” you, but when you need high-quality, reliable spindle repair,

there’s no illusion, rely on Fischer Precise USA.

Fischer Precise USA has over 70 years of experience in spindle manufacturing, maintenance and repair.

Our legacy has been built on the highest levels of customer service and support.

There’s nothing up our sleeves … Fischer Precise USA provides the ultimate in service and repair. Our skilled technicians

are familiar with all major brands.

We have the capabilities, capacity and expertise to restore your spindle to peak...

dare we say it… magical performance.

Visit www.fischerprecise.com to learn more about our repair services, technical support and capabilities.

Not Smoke & Mirrors

High Performance Spindle SolutionsFISCHER PRECISE U.S.A., RACINE, WI 53405 U.S.A.262.632.6173 800.333.6173 FAX: 262.632.6730Email:[email protected] www.fischerprecise.com

COMETOGETHER.

LEAVECONNECTED.

Come together. Leave your mark.LaSt ChaNCe to regISter • ImtS.Com

Where else can you meet the minds that are moving manufacturing forward? Nowhere but IMTS 2014. With a focus on success through cooperation, the week will be filled with technology, education, and ideas that we can all benefit from. Join us at McCormick Place Chicago, September 8–13, 2014. Learn more at IMTS.com.

FraNk keySer Principal Engineer, Automotive Division Molex, Inc.

yearS atteNdINg ImtS5

goaL For ImtS 2014For me, IMTS provides a forum for large companies like mine to connect with smaller ones. We are able to use the show as a way to make new connections, which often lead to partnerships down the road. I’ve also found that IMTS is not only good for seeing the newest technology, it’s an opportunity to learn how to repurpose existing technology for new applications within your industry. That’s valuable stuff.

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