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Strong as a team The market leader qualities and competencies of the SCHLEIFRING group

MOTIONTHE CUSTOMER MAGAZINE OF THE SCHLEIFRING GROUP

EXPLOITING POTENTIAL: Training measures for users

STUDER TECHNOLOGY: Ideal results instantly

COUNTRY SPECIAL – TURKEY: Machines between Occident and Orient

I S S U E 2 / 2 0 1 1

L_S.01_Titel_E.indd 1 20.10.11 15:00

www.winterthurtechnology.com

PROFILE GRINDING WITH WINTERTHUR: PASSIONATELY PRECISE

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

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

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

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

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

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

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

L_S.02-03_Editorial_E.indd 2 19.10.11 18:37

E D I T O R I A L

Know-how is everything

Dear Readers,

The EMO in Hannover, Germany, was again an ex-

hibition of machine tool building. The companies

of the SCHLEIFRING group also demonstrated their

capabilities over approx. 1,000m² - with a large

number of innovations, amongst other things.

In order to develop innovative types of technology

until they are ready for the market in a quick and

high-quality manner, high levels of technical com-

petence are required. Therefore, we pool the

strengths of the individual SCHLEIFRING companies

and fully exploit synergies. This comprises both the

transfer of knowledge of our experts and their edu-

cation and further education. This is complemented

by consistently high investments in research and

development, as well as the integration of knowl-

edge and experience of our customers into the de-

velopment process, as intensively as possible.

No other manufacturer of grinding machines is able

to provide you with such a comprehensive range of

machines, process solutions, and services as the

companies of the SCHLEIFRING group. By network-

ing our international production, service, and dis-

tribution locations, we ensure that all customers can

be supported in a quick and uncomplicated manner

and at the highest technical level all over the world.

You will fi nd more information on these and other

exciting topics in the current edition of MOTION.

3MOTION 02/11

Yours sincerely,

Stephan Nell

Member of the Körber Schleifring GmbH

Management Board

L_S.02-03_Editorial_E.indd 3 19.10.11 18:37

4 MOTION 02/11

CONTENTS

L_S.04-05_Inhalt_E.indd 4 25.10.11 10:23

5MOTION 02/11

C O N T E N T S

IMPRINT

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

Project management: Jan Hawerkamp Art direction: Claudia Schiersch Editorial board: Marc-Oliver Prier (dir), Hauke Burmann, Oliver Haastert , Christina Libuda, Ira Schroers, Sarah

Seyfried, Maresa Wolbert Layout: Stef fi Pflugbeil (dir), Wolfgang Bundschuh, Nadine Ramm Graphic editors: Julia Poppe (dir), Nina Weinhardt Proofreading, editing and translation: Ü-

Werk GmbH Photos: Anzenberger (Titel), bildstelle (1), Corbis (1), culture images (1), dpa (6), iStockphoto (8), Vario Images (2), VISUM (1) Lithography: Fire Dept. GmbH, Hamburg Printing:

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N E W S

18

Current events from the companies

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

Leading trade fair

The SCHLEIFRING group presented

itself at the EMO in Hannover,

Germany

Technology for everybody

Grinding machines are used for many

day-to-day items

Mobile with current

Electrically-powered vehicles with

Fritz Studer AG

Airborne hobby

WALTER employee Christian Marx

fl ies the paraglide

Well-trained

The SCHLEIFRING group

supports users with targeted

training measures

M OT I O N S & M O R E

Country special – Turkey

Machines for the boom on the

Istanbul Strait

20

26

30

38

43

40

06

08

14

18

16

22

24

28

34

COV E R S TO RY

Technical competence of the

SCHLEIFRING group

Achieving the best for the customers

through cooperation

Quality since 1881

Dauphin Precision Tools works with

HELITRONIC machines from WALTER

Grinding gap compensation

MIKROSA provides improved

roundness during centreless angular

plunge-cut-grinding

Optical systems

JUNG precision machines grind lenses for

wafer steppers

Custom-made design in large size

SKF Transrol produces planetary roller

threads with technology from MÄGERLE

StuderTechnology

STUDER software reduces processing

times by 25 percent

Precise, reliable, and quick

The folding spindle technology from

SCHAUDT revolutionises the process of

grinding camshafts

News to use

Practical production tips

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

L_S.04-05_Inhalt_E.indd 5 25.10.11 10:23

6 MOTION 02/11

N E W S

ACCESSORIES

New chain loader from WALTER

HELISET UNO

Reasonably-priced precision

For large diameters: Walter Maschinen-

bau GmbH has designed the new

chain loader 300plus specifi cally for au-

tomatic processing in the woodworking

and metalworking industries. It is used

together with the erosion / tool grinding

machines HELITRONIC DIAMOND and

HELITRONIC POWER DIAMOND. In con-

nection with the HELITRONIC POWER

DIAMOND, the new chain loader now

provides a system which is unique in

the world for producing and re-sharp-

ening tools made of PKD, CBN, HM, and

HSS materials. The chain loader

300plus, designed for different inter-

faces (HSK 63 F, HSK 63 E, HSK 63 B,

HSK 63 A), is able to automatically load

tools with a diameter of up to 320 mil-

limetres and an individual weight of 20

kilograms. The tool loading height is an

ergonomic 650 millimetres so that phys-

ical stress is kept at a minimum, even

Non-contact measuring: the WALTER HELISET UNO allows

control measurements directly in the production depart-

ment and provides ideal conditions for tools and grinding

wheels with diameters of up to 230 millimetres and 370 mil-

limetres of gauge length. The device bed in rigid and stable

cast design forms the basis for permanent precision. The laser

edge fi nder allows for quick positioning of the cutting edge

within the measurement window. HELISET UNO is able to

reach such a high level of performance thanks to image

processing software with comprehen-

sive measuring functions. Improved

tool accuracy and accurately-adjusted

grinding wheel sets form the basis for

higher production quality and notice-

ably save time and costs.

A useful complement:

the chain loader 300plus

from WALTER

THE ADVANTAGES AT A GLANCE:

Quick manual measurement of tools and

grinding wheels

Time required for programming

Minimum demand of training

Quick spot check

Quick focusing of the cutting edge by

means of edge fi nder

Single-hand quick adjustment

at the maximum tool weight. The loading capacity when using tool diameters of

up to 160 millimetres is 35 tools; in the case of diameters of up to 320 millimetres

it is 20 tools.

www.walter-machines.de

www.walter-machines.de

Quick

measuring unit:

WALTER

HELISET UNO

L_S.06-07_News_E.indd 6 19.10.11 18:38

7MOTION 02/11

NEW SERIES

Kick off for the ORBIT series

On the basis of the machines of the ORBIT series, Blohm Jung GmbH extends

its product portfolio to include a completely newly-developed series. It is

designed to set new standards specifi cally in the segment of small- to medium-

scale surface grinding machines and profi le grinding machines. The series com-

prises three machine sizes with grinding ranges between 500 x 200 millimetres

and 800 × 400 millimetres. For this, the customer can choose between two control

variants: a professional CNC control system with controlled drives in all axes, as

well as the established BLOHM easy TOUCH control system delivered together

with a hydraulic X drive. The results of comprehensive market investigations in

Asia and Europe were integrated into the development of the new machine series.

This way, Blohm Jung GmbH ensures that the ORBIT machines meet the current

and future requirements of our customers in an ideal manner.

For 10 years, the overhaul department

of Fritz Studer AG has been restoring

the initial quality of grinding machines

and, in doing so, prolonging the service

life of the machines signifi cantly. The

procedures have been standardised con-

tinuously and the capacities extended so

that the downtime of the machine for the

production of the customer is reduced to

a minimum. A complete overhaul takes

approximately twelve to 14 weeks, with-

in the framework of which the machines

are disassembled completely. Compo-

nents that can still be used are re-worked;

worn components are replaced by genu-

ine STUDER spare parts. The result: old

machines shine in new splendour. So that

the production in the factory of the cus-

tomer does not stand still, STUDER pro-

vides components or entire machines for

hire during the overhaul period wher-

ever possible. A double anniversary is

now approaching : the 250th machine

overhaul is planned for the end of 2011

– just in time for the 10-year existence of

the STUDER overhaul department.

TECHNICAL DATA OF THE

ORBIT MODELS 25/36/48

Grinding range 500 x 200mm to800 x 400mmm

Feed/acceleration values: X axis: max. 40,000mm/min, 2m/s² Y axis: max. 3,750mm/min, 2m/s² Z axis: max. 4,000mm/min, 2m/s²

Output spindle drive: Pole-changeable: 3.7 – 8.0kW Controllable: 4.5 – 7.0kW

Wheel diameters: 200/350/400mm

Compact innovation: The ORBIT series of the BLOHM

brand will be launched in the second quarter of 2012

The launch of the ORBIT 25 series is

scheduled for the fi rst quarter of 2012.

The variants ORBIT 36 and 48 are ex-

pected to be ready for the market in the

second quarter of next year.

Advantages of the

ORBIT series:

Compact cross slide design on the

basis of the established BLOHM

module principle

Best thermal and vibration-related

properties due to FEM optimised

design of all main components in

grey cast iron

Hydrodynamic friction bearing for the

X axis for the highest surface quality

ANNIVERSARY

In the fast lane

[email protected]

L_S.06-07_News_E.indd 7 19.10.11 18:38

SYSTEMATIC SYNERGIES

Community is strength

8 MOTION 02/11

For many years, the companies of

the SCHLEIFRING group have been

amongst the leading providers of grin-

ding machines in the international

market. Even in times of economic tur-

bulence, the group of companies re-

mains a reliable partner for customers

on all continents – and an important

supplier for key industries such as the

turbine, tool, and automobile indus-

tries, as well as the mechanical engi-

neering industry. This has not happe-

ned by chance, but is the result of

future-oriented strategies and innova-

tive machine concepts.

Specialists for all situations

Each brand of the SCHLEIFRING group has its technological special subject. For

example, MIKROSA breaks new ground on the basis of continuous further de-

velopment of processes and applications for centreless cylindrical grinding

machines. These allow for signifi cantly lower unit costs when producing nozzle

needles, amongst other things. Machines by SCHAUDT are also optimised on

a permanent basis and are amongst the best in the market regarding many

production jobs such as processing up to four-metre long rollers. Regarding

tool grinding, on the other hand, the brands WALTER and EWAG are fi rmly

established. Both names are not only known for their machine concepts, but

fi rst and foremost for their unique software solutions for producing and meas-

uring, as well as virtual processing. All programmes are proprietary develop-

ments and, therefore, are perfectly adjusted to the processes. If there are how-

ever applications for surface and profi le grinding of extraordinarily large parts,

then hardly anybody comes close to the industry expert, MÄGERLE.

Innovational strength, technologytransfer and good employees – howthe companies of the SCHLEIFRING group are successfully expandingtheir technical know-how.

C OV E R S T O RY

With power and passion: The

SCHLEIFRING group pools its know-how

L_S.08-13_TG_E.indd 8 28.10.11 15:21

9MOTION 02/11

[1]

[2]

[3]

These examples are representative of

the comprehensive range of services

of the SCHLEIFRING group, further

expanded by the individual companies

with their solution know-how. Here,

synergies are of strategic importance.

By systematically pooling their know-

how, an intensive cooperation between

the individual research and develop-

ment departments, and having their

experts from different grinding dis-

ciplines collaborate closely, the com-

panies of the SCHLEIFRING group in-

crease their innovational strength and

effi ciency many times over. This is

to the advantage of the customers who can benefi t from broad application

know-how and effi cient solutions for each grinding job in this way. “This orien-

tation requires passion, the highest levels of motivation and continuous

learning and optimising,” says Dr. Roland Rütti, managing director with

MÄGERLE and in his function as a member of the management board of the

SCHLEIFRING group responsible for the fi eld of technology. In practice, this

high quality standard is complied with by means of commitment in many areas.

These are, amongst others:

Research and development of innovative systems

Highest-possible customer participation and satisfaction

Explicit quality thinking

Consequent exploitation of synergies

Worldwide service offers

Basic and advanced education of employees

Competent partner for customers in the entire world: The SCHLEIFRING group is a reliable supplier to key industries of the manufacturing sector, for example, in the turbine [1], mechanical engineering [2], and automobile [3] segments.

L_S.08-13_TG_E.indd 9 28.10.11 15:21

Pioneer of grinding machine design

The companies of the SCHLEIFRING group are known for their

innovational strength. For more than 100 years, engineers have

been developing new grinding processes and powerful machines.

Cylindrical grinding

1908 SCHAUDT is awarded the imperial patent for the copy

grinding machine for rod-shaped components

1960 The world’s

fi rst fully automatic

cam shaping

machine (ACM)

by SCHAUDT is

launched

2006 The

STUDER S242 for

turning and

grinding in a

single clamping

operation opens

new perspectives

of economic

production

2011 Using the grinding

software HEUREEKA (see

also page 18) by Schaudt Mik-

rosa GmbH, unprecedented

roundness and axial run-out

accuracies are achieved

during centreless angular

plunge grinding

MILESTONES

there are long-term connections to the Fraunhofer Institute for Production Sys-

tems and Construction Technology (IPK) in Berlin, to the machine tool labora-

tory (WZL) in Aachen, as well as to the Institute for Machine Tools for Manufac-

turing Engineering (IWF) of the Technical University of Braunschweig, and other

institutes (MOTION reported). The companies of the SCHLEIFRING group are

also active on a European level. Blohm Jung GmbH has developed new strategies

for grinding materials for aeroplane engines such as titanium aluminides and

nickel-based alloys. In this way, the novel machine concept of BLOHM PROKOS

arose. Today, customers all over the world benefi t from the capacity of the quick

stroke grinding machine with extreme acceleration and speed values.

Furthermore, competence centres are available for customer trials. “We attach

great importance to maintaining close contact with our customers. They are

incorporated intensively into the process right from the fi rst idea,” says Dr.

Rütti. In this context, the pilot customers are of particular importance. “Without

them we would have never been able to implement some of the developments.”“

It is crucial that the commitment to research and development is not neglected,

not even in the event of tense market situations. Therefore, the SCHLEIFRING

group maintains the budget for this at a consistently high level. This will remain

the case in the future as well so that innovations such as EWAG LASER LINE,

BLOHM ORBIT (see page 7), STUDER S41, or the grinding centre MGC-L-140.50.90

Tradition comes

with responsibilities

The SCHLEIFRING companies have

had know-how in the fi eld of mechan-

ical engineering since the very begin-

ning. In more than 100 years, they have

produced many milestones in the de-

velopment of innovative precision

grinding machines (see box). Without

a constant willingness to invest in the

fi elds of research and development,

this would not be possible. Procedures

are continually researched and proc-

esses analysed and improved in tech-

nology centres which belong to the

companies. The commitment has the

following objectives:

Securing the highest level of quality

Expanding the technology leader-

ship

Increasing the cost effi ciency /

more cost-effi cient production with

the customer

Developing customised grinding

solutions

Offering a fair price-performance

ratio

Here, close cooperation with research

facilities and universities has proven to

be extremely productive. For example,

C OV E R S T O RY

MOTION 02/1110

„The process of networking university-level research activities and industrial know-how advances the development of sophisticated technologies in a quick manner.”Dr. Roland Rütti, managing director withMÄGERLE and member of the managementboard of the SCHLEIFRING group

L_S.08-13_TG_E.indd 10 25.10.11 12:00

Surface and profi le grinding

1925 JUNG launches the fi rst

hydraulic surface grinding

machine

Tool grinding

1953 WALTER presents the world’s fi rst

fully-automatic tool grinding machine

2003 The world’s fi rst

tool-grinding machine which

has direct linear or torque

drives in all fi ve CNC axes

is the HELITRONIC VISION

by WALTER

1997 Well-combined: For

the fi rst time it is possible

to mill, drill, and grind

workpieces on one

machine – an innovation

from MÄGERLE

11

2005 BLOHM PROKOS: The

fi rst quick-stroke contour

grinding machine revolution-

ises the process of grinding

diffi cult-to-machine materials

2011 Technological quantum

leap: With the LASER LINE,

EWAG sets new quality

and productivity standards

for processing super-hard

materials

of MÄGERLE (see page 26) will con-

tinue to be possible.

One-stop solutions

However, research and development

are only one part of the innovational

strength of the SCHLEIFRING compa-

nies. The other part is based on inter-

group cooperation, as well as the proc-

ess of networking know-how and

employees. Many new developments

Taking the lead: The companies of the SCHLEIFRING group promote research and development and rely on networking all grinding disciplines

MOTION 02/11

in the meantime are the result of technology transfer and the exchange of expe-

riences between the experts of the individual grinding disciplines. “For our cus-

tomers, this means that they will always come to the right place with their grind-

ing requirements. We offer the most diverse fi rst-class technologies for grinding,

as well as customised, combined solutions, and comprehensive after-sales serv-

ice from a single source,” says Stephan Nell, managing director of Körber

Schleifring GmbH. And Dr. Roland Rütti adds: “The process of networking uni-

versity-level research activities and industrial know-how quickly advances the

development of sophisticated technologies.” Here, powerful machines and func-

tional groups, new grinding procedures, as well as easy-to-operate and produc-

tion-supporting software are the focus. Three examples from practice:

L_S.08-13_TG_E.indd 11 28.10.11 15:53

12

The process of internationally networking the SCHLEIFRING companies, their serv-

ices, and the know-how of their employees bring the following advantages to custom-

ers all over the world:

Systematic identifi cation of solutions

Process optimisation

Worldwide services for commissioning, repair, maintenance, and overhaul

processes and product support

Quick availability of original, wear, and spare parts and entire replacement

components

Worldwide support by means of a close local network of sales, service, and

application technicians in the corresponding local languages

Effi cient solutions for every grinding job

BENEFITTING FROM SYNERGIES

In the fi eld of cylindrical grinding,

STUDER, SCHAUDT, and MIKROSA

score points with many combined

grinding solutions: For example, dur-

ing the production of nozzle needles,

the guide diameter is initially ground

by machines made by MIKROSA, while

the seats are processed on machines

made by STUDER.

The brands MÄGERLE, BLOHM, and

JUNG network their know-how and

individual strengths in the fi eld of sur-

face and profi le grinding. An example

of this is the exchange of special grind-

ing software and the utilisation of

highly diverse dressing systems for

wheel dressing on the wheelhead or

off the machine table.

WALTER and EWAG have a complete

offer in store for the entire tool

processing. They offer machines for

grinding, eroding, lasering, and

measuring.

Thus, the SCHLEIFRING group acts as

a technology company and a company

providing services. “We are not only a

manufacturer of machines, but a solu-

tion partner for our customers on the

basis of our strong brands. We are able

to offer you customised performance

packages for application, software, and

service from a single source you would

otherwise need at least two to three

different companies for,” says Sieg-

fried Knüpfer, managing director of sales and service of the brands WALTER and

EWAG. In this way, the companies of the SCHLEIFRING group are able to provide

advantages that cannot be found as easily elsewhere – from starting with world-

wide, local services regarding commissioning and maintenance procedures, to

developments of special solutions, to the global supply of the customer base

with genuine spare parts and replacement components (see box below).

The success factor of employees

If nothing else, the employees are decisive for customer satisfaction and creative

ideas. “Their know-how is our most precious asset,” says Nell. They are the

experts and support the customers with their broad application know-how from

the concept phase to the entire lifecycle of a machine in a consulting manner. In

this way, they assist with the immediate implementation of innovative process-

ing solutions. “Our motivation is to increase the competitiveness of our custom-

ers,” explains Nell. Regular training and further education ensure that employees

are always up to date regarding current technological standards and that they

expand their skills.

In order for the knowledge gained to be benefi cial to everybody, it is collected in

special databases. This way, the engineers have access to information on differ-

ent individual grinding solutions. This is useful when developing effi cient software,

for example, as in the case of StuderTechnology integrated. Here, IT experts from

C OV E R S T O RY

MOTION 02/11

Competence centre: Machine production for the

automobile industry with MIKROSA

L_S.08-13_TG_E.indd 12 25.10.11 12:00

Mar

ket

Prod

uct

Fina

nces

Empl

oyee

s

When clamping becomes critical …Extraordinary applications demand

extraordinary solutions. Many work-

pieces cannot be properly clamped

by virtue of their unique characte-

ristics. We develop targeted custo-

mized chucking systems.

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

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

Worldwide, number 1

Worldwide and customer-oriented presence

Worldwide, the strongest brands

Broadest application know-how

Broadest application product portfolio

Broadest application service portfolio

Independent

Reliable partner

Entrepreneurial focus

Most important asset

At home anywhere in the world

The experts

SCHLEIFRING BRAND PROMISE

Fritz Studer AG used the comprehensive data and incorpo-

rated application and grinding-specifi c know-how into the

development. A programme now exists which is able to im-

plement the required calculations and settings more quickly

than any experienced grinder could (see also page 30).

Customer-oriented and powerful

With its eight strong company brands, the SCHLEIFRING group

is the world’s largest provider of grinding machines. It is po-

sitioned in a customer-oriented and powerful manner from

an international perspective. With more than 300 contact

people at 22 production, service, and sales locations, the

companies of the SCHLEIFRING group are present where

the customers are. With the products and services of the

SCHLEIFRING group, you can

operate production in a more

economic manner and con-

sistently develop it further.

Technical competence on site: The worldwide network of local service

technicians is one of the strengths of the SCHLEIFRING group

+ + + p l u e t j e n s @ s c h l e i f r i n g . n e t

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

FURTHER INFORMATION

L_S.08-13_TG_E.indd 13 25.10.11 12:00

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

Finest surface fi nishes:

production control of

end mills with Dauphin

WALTER know how: the process of lapping on the

machine while producing large HSS tools

14 MOTION 02/11

INTELLIGENT AND PRECISE

Each tool a unique itemDauphin Precision Tool is amongst the leading provid-ers of quality tools in the USA. Grinding technology by WALTER participates in the success story.

Only the best is good enough

The above forms the basis for the quality standard of the Americans: “We develop

the best carrier layer, the ideal geometry, the ideal coating, the fi nest surface fi nish,

and the perfect properties for the customer’s specifi c application,“ says Dauphin’s

managing director Bill Coyle. In this, not only are the metal to be processed and

the planned operations of the tool within the metal taken into consideration, but

also the properties of the machine tool in the customer’s production. “At spindle

speeds of 30,000 to 40,000 revolutions per minute, you cannot

take a standard milling cutter from the shelf and expect the

highest levels of productivity,” Coyle explains. The rule of

thumb is: the faster something rotates, the lower the toler-

ance for error is and the more susceptible the part is to

irregularities in geometry or imbalance errors, for ex-

ample. In short: “The quality requirements for end mills

increase when the speeds and the capacities of the

systems rise.”

WALTER machines provide for quality

A decisive working step in the milling cutter production

is taken after tempering the tool blanks. Both for carbide

and for HSS tools, front surfaces, cutting edges, and

clearances must be ground. With Dauphin a fi ve-axis

WALTER HELITRONIC VISION tool-grinding machine

If you are looking for a provider of high-

quality end mills and thread-cutting

taps in the USA, Dauphin Precision Tool

is your fi rst choice. The experts from

Millersburg, Pennsylvania, specialise in

tools made of all types of high-perform-

ance high-speed steel and powder met-

al, as well as different carbide metal

grades such as carbide metals for

through-holes. In the course of its 130

year company history (see box on page

15) the company has produced a large

number of technical tool solutions, al-

ways custom-made for the processing

requirements of its customers.

on, but

duction. “At spindle

nnot

ct the

ule of

er-

o

-

Dauphin‘s pride and

joy: High-precision end

mills made of carbide

L_S.14-15_Walter_E.indd 14 25.10.11 10:41

15MOTION 02/11

Cooling system: specifi cally-arranged nozzles on the HELITRONIC VISION Measurement data: Analysis of workpieces on a WALTER HELICHECK

Effi cient: 3D simulation and programming of the

grinding procedure with HELITRONIC TOOL STUDIO

tom-made distributor system for the installation of rigid high pressure lines was

integrated for each grinding operation. Special high-pressure nozzles are also part

of the precision system. “HSS steels burn quicker than carbide hard metals, even

if you proverbially drown them in cooling oil. However, we have not experienced

anything like that with our cooling system,“ says Cliff Hannar, head of the engineer-

ing and quality monitoring department with Dauphin. This custom-made coolant

supply provides a lower volume at a higher pressure. Moreover, since every noz-

zle is specifi cally oriented towards the spot where cooling is required, thermal

damage is avoided by the system.

Set-up times minimised

The combination of grinding machines, measuring machines, and software also

makes it possible to control the system with only two machine operators. The

grinding wheels are measured on a WALTER HELICHECK measuring machine.

The data is then transferred to the WALTER TOOL STUDIO software in order to

programme the grinding procedure. The 3D simulation created this way shows

an accurate preview of the actual grinding process that can still be optimised in

advance, if required.

Therefore, on the basis of know-how and creativity, Dauphin provides what are

probably the shortest production times for

special tools in the industry and has evolved

into one of the largest suppliers for end mills

made of high-performance high-speed steel

for the demanding aerospace industry.

provides tools with the required quality.

“The outstanding productivity of the

WALTER machines helps us to produce

more tools from solid material,” says

Coyle. Accordingly, Dauphin has invested

considerably in its WALTER systems.

“The HELITRONIC VISION machines have

extremely fast and smooth linear motors

at their disposal, as well as a grinding

motor with 30kW. This way, the best sur-

face qualities are possible in the shortest

grinding times.”

Cleverly cooled

Dauphin has achieved another improve-

ment in effi ciency in the fi eld of cooling.

With two high-pressure nozzles, the

coolant jet is shot at the grinding wheel

at approx. 40bar. Furthermore, a cus-

+ + + e d w a r d . s i n k o r a @ g r i n d i n g .

c o m + + + c h r i s t o p h . e h r l e r @

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

FURTHER INFORMATION

130 YEARS OF KNOW-HOW AND PRECISION

The US tool specialist Dauphin Precision Tool grew out of the long-established com-

pany Brubaker Tool. The company was founded in 1881. In cooperation with its sister

companies FastCut, Weldon, and Data Flute, Dauphin develops high-quality precision

tools for the metal industry. www.brubakertool.com

L_S.14-15_Walter_E.indd 15 25.10.11 10:41

Booth: The companies of the

SCHLEIFRING group showed a

total of 22 exhibits at the EMO

EMO 2011

Grinding technology fascinates the experts

For 34 years, the “Exposition Mondiale

de la Machine-Outil” (EMO) has been

the most important trade fair of the ma-

chine tool industry. The international

event takes place once every two years

in Germany and Italy – once in Milan,

Italy and afterwards twice in Hannover,

Germany. After the last EMO took place

in Milan in 2009, i.e. in economically dif-

fi cult times, the experts now met from

19 to 24 September 2011 in the state

capital of Lower Saxony – however, this

time under a signifi cantly more positive

omen. This is because a large number of

companies in the industry currently face

a positive order situation. This high de-

mand for investment goods was also

clearly noticeable at the EMO. This way,

the organisers were able to record a quite positive summary. The high proportion

of foreign visitors again showed that the EMO is the most internationally-oriented

machine tool trade fair in Europe.

Huge visitor interest

For the companies of the SCHLEIFRING group, this leading trade fair was the most

successful trade fair of all time. Once again, all companies presented together at one

booth. The booth attracted a large number of visitors during the entire event. As in

the past, this Mecca for all prospective customers of grinding technology was located

in an accessible position directly behind the entrance of hall 11. At this booth, visitors

could experience a complete range of different grinding machines. Occupying approx.

1,000 square metres, 22 exhibits from the fi elds of cylindrical grinding, fl at grinding,

and profi le grinding, as well as tool grinding, were available. First and foremost, the

product novelties of the SCHLEIFRING group attracted wide interest. Thus, EWAG

presented their novel laser processing and STUDER presented their new cylindrical

Technology in detail:

Experts of the SCHLEIFRING

companies explained the

scope of services of their

machines to visitors

MOTION 02/11

The technological noveltiesof the SCHLEIFRING group attracted wide interest among the international expert audience at the EMO 2011 in Hannover, Germany.

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

16

E

L_S.16-17_Motions_EMO_E.indd 16 20.10.11 14:55

17MOTION 01/11

At GMN, clocks aren’t ticking faster than elsewhere in the world. Considering the fact however, that we develop high frequency spindles reaching highest rpm per second, it might be assumed that our seconds last longer than usual. By now, we are developing materials and technologies that enable even higher frequencies. And maybe one day, we can even steer the rotating speed of the sweep hand.

www.gmn.de

GMN Paul Müller Industrie GmbH & Co. KG Äußere Bayreuther Str. 230 · D-90411 Nürnberg Phone: +49 911-5691-0 · [email protected]

[email protected]

grinding machine S41 in the 1,000 and 1,600 variants

in Hannover for the fi rst time. A further novelty at-

tracting the interest of the visitors was the fl at and

profi le grinding machine ORBIT from BLOHM. Fur-

thermore, at the booth at the EMO the SCHLEIFRING

group presented itself with the new label “Blue Com-

petence” for the fi rst time. The trade association

“Verein Deutscher Werkzeugmaschinenfabriken”

(VDW – German Machine Tool Builders’ Association)

used this label to honour the activities of the group

of companies in the fi elds of energy and resource

effi ciency and awarded the ecological trademark to

every company.

Grinding trainees in action

However, the SCHLEIFRING group does not only

campaign for sustainable economic management,

but also showed its colours for trainees. This way,

the companies participate in the “VDW-Sonder-

ausstellung Jugend” (youth special exhibition) in

hall 25. Here, young trainees of STUDER present

their apprenticeship and process workpieces on a

STUDER S33 on site.

Good talks: The high demand for grinding

machines was also noticeable at the EMO

Expert audience: Wide

interest in innovative

technology of the

SCHLEIFRING group

Apprentices: The multi-skill

future technicians

Tobias Rapp (li.) and Dominik

Reber at the special

exhibition of the VDW

L_S.16-17_Motions_EMO_E.indd 17 20.10.11 14:55

18 MOTION 02/11

Centreless grinding: The

support prevents the

bending of the workpieces

X axis

Z axis


CROSSED SLIDE SYSTEMS

A well-rounded system

Thanks to a unique machine geometry and clever software, grinding machines of the MIKROSA brand provide unprecedented roundness and axial run-out accuracies in the fi eld of centreless angular plunge cut grinding.

as workpiece and regulating wheel are decisive for ideal roundness during cen-

treless grinding.

Perfect roundness

In order to be able to evaluate these infl uential parameters and to be able to ex-

actly adjust the complex grinding gap geometry, Schaudt Mikrosa GmbH devel-

oped the HEUREEKA software for the KRONOS machines. The programme can

be integrated into the machine control system and is also available as PC version.

As such, it is a particularly helpful tool for planning the grinding process.

HEUREEKA is able to analyse the causes of the polygon error and to determine

During centreless grinding of rota-

tionally symmetric parts, the big

challenge is the roundness of the work-

pieces to be achieved. The cause of

roundness errors can be found in either

the grinding gap geometry, in the work-

piece itself, or in unfavourable machine

dynamics. Frequently, the individual

causes interfere with each other. The

angle ratios of the contact points be-

tween workpiece and grinding wheel,

workpiece and work rest blade, as well

L_S.18-19_Mikrosa_E.indd 18 20.10.11 14:54

19MOTION 02/11

MIKROSA KRONOS S 125: The machine can quickly be converted into a 15° angular plunge

cut machine

Angular plunge cut grinding from the solid: Two operations are

running simultaneously

the KRONOS S series of the MIKROSA brand. For example, outer diameter and

front surfaces of nozzle needles are ground in one clamping. Precise grinding of

the front surface presents a particular challenge. For this, the workpiece must be

ground to “centre”. With the help of the software, the height of the regulating

wheel and the angle of the workpiece work rest blade can be calculated accord-

ingly. In order to achieve ideal chipping, feeding the grinding wheels both in X

and in Z direction is required. “We have solved this problem with a cross slide

system,” says Karsten Otto, Chief Engineer of Schaudt Mikrosa GmbH. “Using

this system, the grinding wheel can be moved in both directions. This also allows

us to compensate the grinding wheel wear in Z direction. This is unique for cen-

treless external cylindrical grinding machines and allows for highly-precise grind-

ing of the front surfaces.” For example, for nozzle needles axial run-out accuracies

of the front surface of 1.5 micrometres are achieved at a roundness of 2.0 mi-

crometres. Regarding turbo rotor shafts, the axial run-out accuracy is 2.0 mi-

crometres. “Furthermore, the cross slide design has an additional advantage: it

makes oscillating plunge cut grinding possible and, therefore, provides an opti-

mised surface quality of the workpieces,” says Karsten Otto. “With the KRONOS

S series we offer centreless precision grinding machines that are characterised

by enormous productivity and extraordinar-

ily high fl exibility in connection with our

intelligent HEUREEKA software. That is what

defi nes modern grinding machine technol-

ogy, in our opinion.”

compensation options. That way, the

ideal grinding gap geometry can be set

for each processing job in order to guar-

antee perfect roundness of the work-

piece. Dynamically-induced errors are

consequences of the compliance behav-

iour of the machine. They can be mini-

mised by means of the corresponding

structural measures such as scraping

the contact faces, compensating the

dampening behaviour, or removing im-

balances. Whether they are the cause

of the out-of-roundness of the work-

piece is clarifi ed by the software by

process of elimination: if the grinding

gap and workpiece geometries are cor-

rect, the machine dynamics must be

responsible for the error.

Unique design

The HEUREEKA software is particularly

effi cient in the fi eld of centreless angu-

lar plunge cut grinding on machines of

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

+ + + k a r s t e n . o t t o @ s c h a u d t -

m i k r o s a . c o m + + +

FURTHER INFORMATION

THE POSSIBILITIES OF KRONOS S

Centreless through-feed grinding

Plunge cut grinding

Plunge cut grinding with long stroke belt

15°/6° angular plunge cut grinding

Plunge cut grinding in multiple production

Grinding of multiple operations in one cycle

Instrumental in

the development

process: Karsten

Otto, chief

engineer at

Schaudt Mikrosa

GmbH

L_S.18-19_Mikrosa_E.indd 19 20.10.11 14:54

Precise optics:

Employee with

lithography lens

20 MOTION 02/11


LITHOGR APHIC SYSTEMS

It’s all about opticsThe production of power-ful memory chips requires ultra-precise optics. JUNG precision grinding machines with customised software are eminently suitable for this.

Lenses for optics

A wafer stepper optics system consists of up to 30 individual spherical and as-

pherical lenses (see box) made of silica glass or Zerodur®. Depending on the

system, the diameter of the lenses is 500 at the most and the height of the lenses

is approx 100 millimetres. Regardless of the size, the requirements regarding

run-out and dimensional accuracy are one millimetre in each case. In order to

meet these requirements, the lenses are produced in several process steps:

grinding, polishing, and fi nal surface coating.

Special software

Precision grinding machines of the JUNG brand with hydrodynamic plain bearing

in the X axis are used for this assignment. “In collaboration with our customer,

One trend within the semi-conductor

industry persists: chips are be-

coming smaller and smaller, faster and

faster, more and more reliable, and

more and more powerful. Simultane-

ously, the high-tech components are

also becoming more cost-effective.

State-of-the-art photolithographic pro-

duction systems, so-called wafer step-

pers or wafer scanners, with highly

precise optical systems and lenses are

the prerequisite for this. Grinding is the

decisive working step for the production

of the lenses. The better the ground

surface is, the lower the time required

for further processes will be. Therefore,

many manufacturers of optical systems

decide in favour of JUNG precision

grinding machines.

SPHERICAL LENSES

Spherical lenses have the same radius in

every location. On the contrary, an aspher-

ical lens has a different radius in every

location of the lens. The different curvature

of the lens surface improves the imaging

quality of the lens particularly strongly in

the area of the margin.

L_S.20-21_Blohm_E.indd 20 20.10.11 14:53

Before: An optical lens made of silica glass in its initial condition

Broad fi eld of application: The CNC-controlled JUNG

VARIO with plan bearing for highest surface quality

After: The optical system of a wafer stepper consists of up to 30 individual lenses

machines and the close cooperative collaboration with the application technol-

ogy were decisive for the customer,” says Hußlik. “Since the introduction of the

JUNG machines, the company was able to improve the quality of the optical

lenses signifi cantly and to decisively increase

the overall availability of the machines.” In the

meantime, three further structurally-identical

JUNG precision grinding machines manage

the production for the arising new orders.

we developed a special lens-grinding

software and a special sensory sys-

tem,” explains Matthias Hußlik, area

manager for Baden-Württemberg with

Blohm Jung GmbH. The lens to be

ground is clamped to a rotation axis by

means of a vacuum. Depending on the

size of the lens, the axis will rotate per-

manently with up to 550 rotations per

minute. The lens contours are proc-

essed by means of the belt grinding

procedure with very fi ne diamond grind-

ing wheels. In order to rule out or pre-

vent as many negative effects on the

surface quality as possible during the

grinding procedure, corresponding

measures were taken. “A special ce-

ramic bearing reduces the oscillations

of the spindle, which is furthermore

permanently monitored by vibration

sensors. Moreover, the optimised con-

trol and parameterisation of the ma-

chine axes also provide a contribution

to an excellent surface quality of the

lens,” explains Hußlik.

Quality improved signifi cantly

“One of our customers initially worked

on special machines with cup-grinding

wheels. First and foremost, the hydro-

dynamic plain bearing system of our

+ + + d i e t h a r d t . l i e s a c k @

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

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

FURTHER INFORMATION

21MOTION 02/11

L_S.20-21_Blohm_E.indd 21 20.10.11 14:54

GRINDING TECHNOLOGY IN DAY-TO -DAY L IFE

Technology for everybody


Hardly anybody knows that many articles used in daily life can

only be produced with the help of grinding machines. This is

not only applicable to industrial products, but also to many prod-

ucts such as bottles, refrigerators, and fountain pens. MOTION

presents some items used on a daily basis which also include a

bit of know-how of the SCHLEIFRING group.

What do a turbine, a vacuum cleaner, and a PET bottlehave in common? Technology from companies of theSCHLEIFRING group is used in order to produce them.

Safety forroad traffi c

JUNG machines

produce tools

for the manufacture

of tail lights

Sewing machines

Highly precise: The S33

from STUDER grinds

gripper components

for sewing

machines of the

BERNINA brand

round

Refrigerators

Well-cooled: Compressor shafts for

refrigerators are ground by MIKROSA

and SCHAUDT machines

22 MOTION 02/11

Drill bits

Quality convinces – many tool manufacturers use

grinding machines from WALTER for their production

Fountain pens

Deluxe writing instrument:

Fountain pens of the Montblanc

brand are hand-made. The tools

required for this are produced

on STUDER and JUNG machines

L_S.22-23_Schleifmaschinen_E.indd 22 20.10.11 14:52

23MOTION 02/11

While travelling

Turbine blades are

ground fi rst-class

on BLOHM and

MÄGERLE machines

A good trip

Machines from the

SCHLEIFRING group

put vehicles in gear.

For example, SCHAUDT

is the leading specialist for

camshaft processing

Like a Swiss watch

The watch industry increasingly uses

precise EWAG machines in the fi eld of

housing production

PET bottles

Light and unbreak-

able: Tools for PET

bottles, as used

by companies such

as Acqua Minerale

San Benedetto,

are produced with

the help of

a STUDER S31

Vacuum cleaners

Away with the dust: The

KRONOS M 250 by MIKROSA

provides for perfect shafts of

the electric motor

Chain saws

Sharp and powerful:

Pinion shafts and chain

pins are ground on

KRONOS machines

of the MIKROSA brand

L_S.22-23_Schleifmaschinen_E.indd 23 20.10.11 14:53

renewable energies in cooperation with future-oriented partners from the fi elds of

economy, science, politics, and tourism,” says Urs Böhlen, overall project manager

for electric mobility of the RWK. In the fi elds of environment, climate, and sustain-

ability, the RWK develops groundbreaking, integral, and practice-oriented solutions

with transregional signal effect together with its partners. As its vision, environ-

mentally-friendly vehicles are expected to account for approx. 20 percent of traffi c

in the region before 2025. In order to reach this ambitious objective, there still is

some work to do. Fred Gaegauf, RWK president and managing director of Fritz

Studer AG: “Additional vehicle charging stations are required. We are currently

further expanding the existing network together with a local energy provider.”

The Swiss Federal Institute of Technology in Zurich, a long-time partner of Fritz

Studer AG, has implemented its own electric mobility project. Professor David

Dyntar of the Institute for Machine Tools and Production designed the so-called

SunCar on the basis of the Lotus Evora together with his students. The sports ve-

hicle is equipped with solar modules and utilises the energy of the sun. The solar

pioneer Dyntar uses the electric vehicle for private purposes as well: “The roof of

my house is equipped with 30 square metres of solar modules. After a charging

period of six hours, I can drive distances of approx. 400 km with solar energy.”

S242 grinds electric motors

With regard to electric mobility, Fritz Studer AG has another iron in its fi re: the

versatile S242 (see box) is extremely suitable for processing and producing electric

motors. It allows for hard turning and grinding in only one clamping operation.

“The commitment to electric mobility is

near and dear to us,” emphasises Fred

Gaegauf. “Some fl oat with the current, we

use it to drive.”

Using the current to drive: Fritz Studer AG

is committed to electric mobility

FURTHER INFORMATION

24 MOTION 02/11

ELECTRIC MOBIL IT Y

STUDER energisedMore electrically powered vehicles are expected around the Swiss city of Thun. The initiative is supported by the cylindrical grinding experts of Fritz Studer AG

They are noiseless, cost-effective re-

garding maintenance, and environ-

mentally-friendly – electrically-powered

vehicles drive without producing any

CO2. The carbon-neutral technology is

being promoted all over the world. For

example, the regional economy coordina-

tion of Thun (regionale Wirtschaftskoor-

dination – RWK) is building an e-cluster

for renewable energy sources and electric

mobility in the Bernese Oberland in Swit-

zerland. The fi rst initiatives have already

borne fruit: for example, Fritz Studer AG

has expanded its fl eet of vehicles by two

electrically-powered vehicles of the

ThinkCity type. Fully charged, they have

a cruising range of 160 kilometres.

Centre for electric mobility

“Our objective is to establish the eco-

nomic area of Thun as a competence

centre regarding electric mobility and

STUDER S242

The STUDER S242 is a true all-rounder: The

combination processing machine combines

the techniques of cylindrical grinding and

hard turning in an ideal way. It produces

functional surface structures and is char-

acterised by low primary and secondary

processing times. Furthermore, the operator

saves up to 70 percent of the conventional

processing time when using the machine.+ + + m i c h e l e . f a h r n i @ s t u d e r . c o m

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


L_S.24-25_Studer_E.indd 24 03.11.11 10:24

25MOTION 02/11

Gauging and control for grinding machines

Absolute measuringsystem for parts with a large measuring range

Leading...

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

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

...results from the perfect combination

of many factors

Acoustic sensors for grinders

Grinding wheel balancing systems

L_S.24-25_Studer_E.indd 25 19.10.11 18:52

26 MOTION 02/11


SCREW DRIVES

Some like it largeWithin the SCHLEIFRING group, MÄGERLE engineers are the experts for the high-est precision regarding large and heavy-weight workpiec-es. The Swiss develop cus-tomised solutions for diffi cult assignments – such as the MGC-L-140.50.90.

Chambéry – a French city with 57,000

inhabitants at the foot of the Savo-

yard Alps, bordered with mountains

and wine-growing regions. The head-

quarters of SKF Transrol can be found

in this scenic environment, a subsidiary

of the Swedish SKF corporation. The

company was founded in 1968 and is

one of the world’s largest producers of

planetary roller screw drives. In such a

screw drive, ground rollers rotate

around a spindle – similar to the planets

rotating around a central star. Such

screw drives allow for higher force

transmissions when compared to ball screws. The linear drives are particularly

suitable for high loads and medium speeds. Planetary rollers are used where

high loads are also in demand under diffi cult conditions - for example, in the

fi elds of aerospace and automotive manufacturing, and for presses. Classic fi elds

of application include fl aps and chassis of aeroplanes, positioning systems for

space travel, control cylinders for vehicles and construction machines, closing

systems for injection moulding machines and presses, as well as fi nal drives and

cylinders in the engineering industry.

Workpiece confi guration:

precision is in demand

Designed for

large

dimensions:

working area

of the

MGC-

L-140.50.90

L_S.26-27_Maegerle_E.indd 26 19.10.11 18:52

27MOTION 02/11

+ + + g i l b e r t . l e u t w i l e r @

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

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

FURTHER INFORMATION

MÄGERLE MGC-L-140.50.90

With the MGC-L-140.50.90, the experts from Mägerle AG

developed a machine ensuring the highest level of precision

when processing in one clamping operation. The grinding

centre is designed for vertical cylindrical grinding of inner

and outer diameters, as well as for grinding inner threads.

The workpieces are positioned and clamped on the mag-

netic clamping plate by means of a lifting and centring de-

vice. The machine is equipped with a 180-degree NC swiv-

elling head with two vertical spindles. The operator can

swivel it by ±20 degrees and adjust it in accordance with

the thread pitch. The 24 ton machine is characterised by its

high rigidity.

Robust and quick

Planetary roller screw drives are able to accept high loads under unfavourable

conditions over thousands of hours of operation and, thus, are suitable for the most

demanding applications. They achieve effi ciencies of up to 90 percent. A synchro-

nisation mechanism provides for proper functionality at high acceleration. The

high pitch allows for high linear speeds. On the basis of the large number of contact

surfaces, the threads transmit and position high forces in a very precise manner.

The electro-mechanic lift and adjustment drives for linear movement are energy-

effi cient, because they require no hydraulic oil and, thus, no hydraulic aggregate.

Reliable partner

Jean-Paul Giraudeau and the employees of SKF Transrol, who number approxi-

mately 230, have set the bar very high. They intend to maintain their good market

position and continue to provide their custom-

ers with high-quality planetary roller screw

threads from Chambéry. “Of course”, he says

smiling, “we will continue to rely on Mägerle

AG as a reliable partner in the future as well”.

Maximum precision

“For us, planetary rollers are a strategic

market, which is why we produce them

on a large scale”, says Jean-Paul Girau-

deau, head of process and quality with

SKF Transrol. In order to meet this chal-

lenge, the company contacted the grind-

ing experts of Mägerle AG. They were

commissioned with the delivery of a

solution for maximum precision for very

large and heavy-weight components.

The result: the MGC-L-140.50.90 – a ma-

chine whose concept convinced the

French (see info box). “Thanks to coop-

eration with Mägerle, we have a real

competitive edge when it comes to pro-

ducing rollers with large dimensions”,

says Giraudeau.

Schematic

representation:

the MÄGERLE

MGC-L-140.50.90

Competence from Fehraltorf: the experts of MÄGERLE are always ready for

new, complex grinding assignments

Ground in one clamping

operation: threaded nuts for

planetary roller threads

L_S.26-27_Maegerle_E.indd 27 19.10.11 18:52

28 MOTION 02/11


Boundless freedom:

Christian Marx

fl ying over

the Rift Valley

PARAGLIDING

An airborne pleasure

Asolitary paraglide fl oats over the

Kenyan Rift Valley. The paraglide

is controlled by Christian Marx, em-

ployee of Walter Maschinenbau GmbH.

After four hours of fl ying over the

breathtaking African landscape with

waterfalls and countless bushes, he

slowly lowers the aircraft. The landing

site is already crowded by native chil-

dren who have gathered in order to

greet the man coming from the sky.

Although paragliders are not an unu-

sual sight in this region, such a landing

is always a welcome change for the

Kenyans. Once, Christian Marx was

immediately surrounded by 200 cu-

rious natives he could present his paraglide to. He even received a fair amount

of applause for this.

Impressive experiences

Normally, Marx is not used to such an exuberant reception as in Kenya. He most-

ly fl ies in the Alps and particularly likes the French region of Annecy. “There, I can

very quickly get into conversations with other paragliders,” says Marx. “The

solidarity between the paragliders is huge. We warn each other regarding hazards

and provide each other with tips regarding the fl ying area.” The software engineer

with the airborne hobby has already had many impressive experiences: “One day,

I fl ew through a cloud – that was really spooky. Since then I utterly respect this.

Affectionate reception: afterhaving landed, Christian Marx is

surrounded by Kenyan children

Walter employee Christian Marx likesto see the world from above. In hisspare time the 35 year old regularlytakes to the air with his paraglide.

L_S.28-29_Hobby_E.indd 28 20.10.11 14:51

29MOTION 02/11

Annecy: good

fl ying areas for

paragliders exist in

the French Alps

[email protected]

Another time I circled right next to a sailplane

and could look directly into the cockpit at the

pilot,” says Marx.

Thrill during takeoff

The IT expert, who has been working for

WALTER for more than ten years, started his

hobby with a taster course at a fl ight school

in Tübingen, Germany. Afterwards, he re-

ceived his pilot’s licence and bought his own

equipment. Paragliding is not a cheap hobby:

“The equipment alone costs approx. 3,500

Euros. In addition, you must pay approx. 1,500

Euros for the pilot’s licence,” says Marx.

With good training, the risk of accidents is

kept within reasonable limits. “I would com-

pare it to riding a motorcycle – if you do not

get too cocky, the risk is low,” says the 35

year old. Despite approx. 40 fl ights per year,

takeoff still gives him a great thrill each time.

He has even convinced his cousin to pa-

raglide: they fl y together through the Alps

twice a year.

High above the rooftops

of Queenstown

Normally, Marx uses his annual vacation in

order to discover special fl ying areas. For ex-

ample, he has even fl own in New Zealand. “In

Queenstown, it is even possible to fl y direct-

ly over the town. This is not possible in dense-

ly-populated Europe,” says the enthusiastic

paraglider. “From above, a city looks just like

a model railway layout,” he adds, fascinated.

However, he is still the most excited about

Kenya. Marx soon wants to enjoy the sky

above Africa with his paraglide again.

PARAGLIDING

For paragliding, the pilot is located underneath the paraglide in a

harness and is connected to the paraglide by means of ropes. Al-

though a paraglide looks like a parachute, it is actually an aircraft.

The principle is similar to that of a sailplane: the pilot fl ies with the

help of updraughts and thermals. The fi rst real paraglide was in-

vented in 1965 by David Barish with his 5-arched Sailwing. Just like

modern sports parachutes, today’s models are based on the two-

layer multi-cell parafoil parachute concept by Domina Jalbert. Up

until the 1970s, paragliding was limited to quickly fl ying down into

a valley. Further technical developments in the 1980s ultimately made

true fl ying possible.

Back on solid ground: natives

marvel at the paraglide

Kenya: village children curiously

observe the European paraglider

Bird’s eye view: Christian

Marx looking down on the

Lac d’Annecy

Over the land of the Kiwis: panorama in new Zealand

L_S.28-29_Hobby_E.indd 29 20.10.11 14:52

30 MOTION 02/11


GRINDING SOF T WARE

Perfection at the push of a button

The IT experts of Fritz Studer AG have developed StuderTechnology grinding software which instantly delivers ideal results during cylindrical grinding and simultaneously reduces the processing time by approx. 25 percent.

Today’s cameras make it easier to

shoot good pictures when compa-

red to former times. As opposed to 20

years ago, today‘s cameras are able to

automatically select settings such as

the aperture, the light sensitivity, or the

exposure. There is now a similar deve-

lopment for cylindrical grinding ma-

chines of the STUDER brand.

The right setting - instantly

Also here every component manufac-

tured on the machine depends on the

correct settings. First, the user must se-

lect the corresponding grinding wheel. Furthermore, the cutting speed, the cooling

lubricant, the stability of the workpiece, critical speed ratios, and the infl uence of

the grain size on the grinding wheel must be checked. “Even if an operator has a

wealth of experience, he does not usually manage to instantly set the machine in

an ideal manner,” says Erhard Kämpf, head of the department of Forms and Threads

with Fritz Studer AG. The optimum would be the setting with which the machine

precisely achieves the desired grinding result and simultaneously works most ef-

fi ciently. Normally, this setting can only be found by means of systematic tests.

“This takes time and, thus, is only reasonable when producing large numbers. For

a few hundred units or even smaller production volumes up to single-item produc-

tion, the operators do not normally have the time to slowly approach the perfect

Quick and cost-effi cient:

StuderTechnology

saves time and money

L_S.30-33_Studer Technology_E.indd 30 20.10.11 14:50

31MOTION 02/11

Empirical values: StuderTechnology includes the entire 100-year experience of

the Swiss cylindrical grinding experts

Simple solution: as with a camera, automatic programmes adjust the most

important grinding parameters

additional programme contains the entire near-100-year experience of the Swiss

cylindrical grinding company. The engineers from the Swiss city of Thun supplied

StuderTechnology with the data from countless grinding tests, for which they ap-

proached the optimum for the most diverse workpieces again and again. The result:

in analogy to the state-of-the-art camera, a machine equipped with this system

makes many decisions for the operator. The module determines the most important

process-relevant infl uencing variables and the corresponding values automati-

cally for each processing step. “In this way, improved results can be achieved while

simultaneously shortening processing times signifi cantly,” says Kämpf. His team

calculated that the processing time, in most cases, can be reduced by at least a

quarter with StuderTechnology. For example: using an average universal grinding

setting,” explains Kämpf. Therefore, they

mostly rely on their gut feeling regarding

the values for dimensional, shape, and

position tolerances, as well as surface

quality. This results in the following

problem: the majority of users underes-

timate the machining output of a grind-

ing wheel and, therefore, rarely dare to

approach the limits of what is possible.

They often adjust the machine too cau-

tiously and do not utilise its full potential.

Thus, the production runs at a speed

which is much slower than what is pos-

sible. This way, the companies waste

large amounts of time and, thus, money.

Savings of hundreds of

thousands of Euros

Fritz Studer AG has driven an innovation

in this area and now offers a unique soft-

ware solution that can be of signifi cant

value to companies: the grinding tech-

nology calculator StuderTechnology.

This is available as a practical module

of the CAM system StuderGRIND. This

THE ADVANTAGES OF STUDER TECHNOLOGY

Automatic calculation and design of the process parameters

Direct integration of 300 machine parameters and a database

Integrated grinding know-how that can be expanded, optimised, and reproduced

Technological analysis, monitoring, and graphic feed curves

Graphic simulation of the grinding programmes

Automatic reporting for the creation of set-up plans, tool lists, additional comments,

and images

Time and cost calculation, quoting

Reduction of the set-up times

Shorter grinding times by approx. one quarter

Reduction of the optimisation time towards zero

Reduction of the error costs


32

Full speed ahead: the

material is more resilient

than many grinders think

MOTION 02/11


machine operating in two-shifts, pro-

ductivity can thus often be increased to

such an extent that a company can save

large amounts of money each year. “In

this way, the purchase of the module

often pays for itself after a short period

of time,” says Kämpf.

One software – two variants

Recently, the grinding technology calcu-

lator has become available in two differ-

ent versions. For customers operating

their own programming offi ce within

their company, the full version of the

software is available. Using this version,

it is not only possible to programme the

machines on a PC to an ideal standard,

but also to display simulations graphi-

cally, to calculate unit costs, or to gener-

ate operation schedules (see box on

page 31).

As the latest development, StuderTech-

nology integrated has now been added.

In this version, the software is no longer

located on a separate computer, but directly on the machine control system. Using

this easy-to-operate variant with a range of functions which is reduced to a work-

shop level, Fritz Studer AG provides the machine operators with more freedom in

their everyday work. They need only enter the material and will immediately be

provided with a suggestion regarding the correct grinding material and the ideal

process parameters. Without tedious trial and error, an ideal result can be achieved

at the push of a button in a few seconds. The customer benefi t is indeed so high

that StuderTechnology integrated will in the future become a standard part of the

basic equipment in all machines equipped with the new operating system Studer-

WIN. In this way, customers will always

benefi t from the know-how and the

grinding experience of Fritz Studer AG

in the future.

Ideal feed: StuderTechnology determines the appropriate values for each workpiece

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

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

FURTHER INFORMATION

”Using StuderTechnology, it is possible to achieve improved results and simultaneously reduce processing time significantly.“Erhard Kämpf, head of department Forms and Threads,

Fritz Studer AG


Keeping our ear to your process

Das Ohr am Prozess

Prozessüberwachung und -steuerung für Schleif- und KombimaschinenProcess monitoring and controlling of grinding and combi machines

USA / CANADAGTI SPINDLE TECHNOLOGY, INC.

Manchester, New Hampshire

UK / IRLANDREPCO TECHNOLOGY LTD.

Coventry

SWEDEN / NORWAYADAMANTGöteborg RUSSIA

EUROSHLIF LTD.Moskau

ITALYSERMA S.R.L.Bologna

GERMANYDITTEL MESSTECHNIK GmbH Landsberg am LechSPAIN

COHERSA INDUSTRIAS S.A.Castellbisbal

JAPANFUKUDA CORPORATIONTokyo

KOREADG TechnologySeoul

CHINAUNIVERSAL HONGKONG TECHNOLOGY CO., LTD.Beijing

TAIWANJOIN STAR TRADING CO., LTD.Taipei

INDIANN COMBINED

ENGINEERING AGENCIES PVT. LTD.

Secunderabad

BRAZILGMN Brasil Ltda.

Alphaville, Barueri – Sao Paulo

Phone: +49 8191 3351-0 Fax: +49 8191 [email protected] www.dittel.com

Dittel Messtechnik GmbHErpftinger Str. 36 86899 Landsberg / Lech Germany

Prozess- / Zustandsüberwachung Process control / Condition Monitoring

Wuchtsysteme / Balancing Systems Sensorik / Sensors

Unsere Vertriebspartner weltweit / Our Agencies worldwide



34 MOTION 02/11

The machines of the SCHLEIFRING companies can tap their potential best when users are familiar with handling the machines. A comprehensive training offer for customers from all over the world conveys important know-how.

Tapping the full

potential: training

users at Fritz Studer AG

TR AINING MEASURES

Fit for everyday grinding

The possibilities of modern grinding

machines are very complex. During

setup and when programming grinding

processes, comprehensive settings

must be implemented. Even if, today,

innovative software solutions and ma-

chine control systems facilitate han-

dling – operation remains challenging.

Often, the systems work at the technical

limits so that operators cannot always

proceed with mere intuition. In order to

be able to tap the full potential of the machines, the experts of the SCHLEIFRING

companies recommend using the training offered. Here, the training programme

is as comprehensive and individual as the requirements of the customers.

Basic courses for beginners

Normally, customers are familiarised with the machines in different steps. For

example, Blohm Jung GmbH does not only offer standard packages for handling

the user interface, but also additional training for the user software BLOHM pro-

Practical: customers in front of a machine control system

L_S.34-37_Schulungen_E.indd 34 20.10.11 14:49

35MOTION 02/11

launched. For example, Fritz

Studer AG supported the launch

of the cylindrical grinding ma-

chine S41 at an early stage with

the development of a specifi c

training offer. However, the

greatest need for information

arises when new software is

launched parallel to a new ma-

chine. “At the time we launched

the HELITRONIC MICRO, this

machine could no longer be

operated with our old software,

but only with TOOL STUDIO,”

explains Jochen Reiff, head of

Application Technology Ger-

many with Walter Maschinen-

bau GmbH. “Back then, we not

only had to familiarise the customers with a new robot and a different axis con-

fi guration, but also simultaneously with the new IT system.” Even customers who

are already familiar with the programs should make use of the offered training

measures at regular intervals, emphasised Reiff. If, for example, a new version

of the operating software is launched, the users could continue working nor-

mally with their present skills. However, the additional possibilities of the new

functions would only be comprehensible to them after a specifi c training course.

Before and after delivery

“If possible, we recommend taking a course on the corresponding software and

on handling the machine before a new system is delivered, in order to become

familiar with all of the particularities,” explains Hans Frey, Customer Service

manager with Schaudt Mikrosa GmbH. “It is best if the participants initially take

fi le. “However, sometimes people with

little to no previous knowledge contact

us,” says Peter Oppelt, head of Applica-

tion for BLOHM and JUNG. “We offer a

basic course, “Grinding”, specifi cally

for them, in which we explain, among

other things, the types of grinding

wheels and how workpieces are

clamped. We want to provide the par-

ticipants with a feeling for what kinds

of effects the change of different pa-

rameters has on the result of the work.”

For beginners in the fi eld of grinding,

Fritz Studer AG has even designed a

separate simulator which the partici-

pants of the basic courses can use to

initially practice the fi rst steps for dif-

ferent cylindrical grinding machines “in

a dry run”.

Know-how for

machines and software

Even for experts in the fi eld of grinding,

there are a large number of operator and

programming courses in which specifi c

know-how of certain machine types is

conveyed. For example, after basic and

extended training for the EWAMATIC

LINE, customers of Ewag AG can also

receive instructions on how to pro-

gramme specifi c, complex cylindrical

parts or how to set up the robots. The

demand for training is always particu-

larly high when new machines are

Imparting

knowledge: a

customer is

familiarised with

machine details

Seminar passed:

Martin Theurer

from WALTER (left)

congratulates

course participant

Guido Weber


36 MOTION 02/11


in the large training centres. By contrast, other companies such as Mägerle AG

predominantly produce special machines which are developed exactly in ac-

cordance with the requirements of the customers. Training must be designed

correspondingly in an individual manner. “Since all machines are different, the

customers are always trained by the employee who knows the system best,

including all of its specifi cations. Normally, this is also the application technician

who is familiar with the specifi c production processes of the companies,” reports

Markus Rinne, head of Process Engineering with MÄGERLE.

Training at the customer’s premises

Furthermore, training measures implemented on site with the customer form an

important part of the training concept. This is helpful since the need for clarifi ca-

tion often arises during operation. Regardless of whether new employees must

become familiar with the machine or new production jobs must be mastered with

changed production procedures, the companies of the SCHLEIFRING group can

help in these cases as well. For example, WALTER has established a global net-

work of more than 50 application

technicians supporting the op-

erators directly within their com-

panies regarding machine han-

dling all over the world. For

BLOHM, JUNG, and MÄGERLE

machines, there are also targeted

training sessions in the factories

of the customers to refresh the

contents of previous training in

real conditions. If this is not suf-

fi cient, customers can ask ques-

tions about their grinding proc-

esses at any time using service

hotlines for all brands.

Training certifi cate: users are provided with certifi cates for the courses

they have passed with EWAG as well

an operator or programming course for

the machines and, shortly thereafter, a

specifi c software course for their own

processing assignments,” adds Stephan

Frei, head of Training with STUDER.

However, especially when participants

come from overseas, these training

courses are often booked in blocks due

to time restraints. In this case, there is

a huge amount of new information at

once. It is then very helpful that there

are frequently more lively practical ex-

ercises than dry theoretical units for the

participants during the seminars.

Many practical exercises

“The best method of learning is to do

it yourself,” is the motto of Peter Op-

pelt. Therefore, with Blohm Jung GmbH

the customers can already stand at the

controls themselves and learn how to

correctly operate the machine super-

vised by a competent person when ac-

cepting a purchased machine in the

factory in Hamburg, Germany. In gen-

eral, training participants can practice

with exactly the machine they have pur-

chased, or they can be provided with a

model of the same series. For example,

at STUDER and WALTER, training ma-

chines of all models are available with-

TRAINING OFFERS

Basic courses grinding technology

General operator and programming courses

Software courses

Maintenance courses

The training classes last two to four and a half days and are intended for two to six participants with or without previous knowledge. In addition to the standard courses, there are individual offers and corrective training courses at the SCHLEIFRING companies or worldwide with the customers on site.

Learning for everyday

grinding: an employee

(r.) of Ewag AG with

customers in front of

an EWAMATIC LINE


37MOTION 02/11 3733733373373737773373773773773777733333337733733377777MOTMMMMOTMMMMMMOTMOTMOTMOTTMMOMOMOTMMOTTMOTTMOTMMMMMMMOMOTMOMOMOMOTMOTTOTOTMMMMMMMMMMOOOOTOTOMOTOTTTTTMOTOTOTMMMMMMMMOMOMOTOTTTTMOTOTMMOTTTMMMMOTTTTTMMM TIOOOIOIOOOOOOOOOOONNOONNIOIOIOOOOOOONOONNNNIOIOOOOOOOOOOONNNNNNNNNNNNIOIOIIOOOONNNNNIOOONNIOONIIOIOONNIIOONIONIIOOOIONN 020200000222202020202020200002022222202020200000020222222222 02202020200002222220222222 0202020222 02202002222022 02222 02222002202222/1/1////11111111111////1/11111111///////1111111///1/111/111////1/11/1/1/1/1111//1/1/11/1//// 333337373737373777733337373333337373777333733337333337373373377333333733MOTMOTMOTMOTMMMOTMOTOMOMOTOOOOOOOOOOOOTMOTMOTOTMOMOTMOTMMMOTMOTMOMMMMMMOTMOMOTTMOTMOTMMMOTMOMOTMMMMMOTMOTMOMOMMOTMOTMMMMMOTMOTMOTMOTOTMMOTMMMMOTMOTMMMOTMOMMOMOTMOTOTOTMMOTMMMOOOMOMOTMOTMOTMOTMOTOTMOTTOTMOTMOOOMOTOTTMOTTMMOOOOOTOOTOTTMOTTTTTTMMMOMOMOTMOTOTTTTMOOTTTTMMM TTTMMMMOOOOOOTTTTMMOOOOTTTIOIOIIOOOOONOOONONNNIOOIONOONOONNNNNNNNNNIONONOOOIOOONONNNNNNNNNNNIONIONIONOOIONONOONNNNNNNIONOIOIOIOIOOONONNNNNNIOOOIOOOOOONONNNNNNNNIONOOOOOONNNNNNNNNNNNIONOOOOOOOOONNNNNNNNNNNIOIOIIIIIOOOOOOOONNNNNNNIOIIOOOOOONNNNNNNNNIOIOIOIOOOOONNNNIOIIOOOONIOIIIOONIIOONNNN 0000020200202002022022222220202002022222220200202222020022022200002220022222200022222222222202220222222220022222222202202222222222202222222/11////////11111/1111//////11/111111/1111/////111/1/1/1//1/11/1/111/11/1/1/1/1/1111///1/1/1/1/1/1/111/111/1///1/11/1111111///////11111111111//1//11111/111////111111/11//111//////11

sharp by nature

www.meister-abrasives.com


38 MOTION 02/11


CAMSHAF T GRINDING

The perfect shaft

Using the self-developed, patented swivel-in spindle technology, SCHAUDT machines grind camshafts of any type in a precise, reliable and faster manner.

It was in 983 in Tuscany, when convert-

ing a mechanical rotary movement

with the help of elevations (cams) on a

shaft into an upwards and downwards

movement was managed for the fi rst

time. Without this development, the en-

tire industrial revolution in the 18th cen-

tury would not have been possible. To-

day, the camshaft is still an important

part of modern reciprocating piston en-

gines – regardless of whether they are

for a train or a passenger vehicle.

Decisive invention

Schaudt Mikrosa GmbH has been the

technological market leader regarding

the production of camshafts for many

years; the company has nearly 100 years

of experience in this fi eld. More than any

other brand, SCHAUDT has perfected the

process of grinding concave cams since

then: “Our systems are suited extremely

well to the time-saving complete machin-

ing of the most diverse camshafts in one

clamping operation,” explains Daniel Mavro, Head of Technology and Process En-

gineering. With the SCHAUDT CamGrind series, for example, different bearings and

cams can be ground simultaneously. A huge advantage for the customer – a techni-

cal challenge for the engineers, since a relatively small grinding wheel is used when

grinding cams with a concave radius. By contrast, a large wheel makes sense for

other areas, such as the bearings for the shaft. In order to still be able to process

the different elements simultaneously, the engineers had to come up with something

special. The decisive technology is their own invention from the 1990s which has

continuously been further developed since then: a swivel-in spindle which can be

pivoted and guided to the workpiece within two seconds. Here, a hydraulic cylinder

folding the spindle down for grinding purposes replaces an additional B axis with-

in the machine. “With another axis, the production would by no means be as cost-

effi cient, quick, and fl exible as it is with our procedure,” reports Mavro.

Massive economy of time

With the SCHAUDT CamGrind series, two of these practical spindles have been

used lately. These can be converged very narrowly so that only a gap of twenty

millimetres remains between the grinding wheels. This innovation now makes

it possible to grind up to four different cams at the same time while simultane-

ously reducing the processing time by a signifi cant 30 percent. The auxiliary

Daniel Mavro: Head of Technology andProcess Engineering at Schaudt Mikrosa GmbH

L_S.38-39_Schaudt_E.indd 38 19.10.11 18:56

39MOTION 02/11

Cost-effi cient and

quick: The

swivel-in spindle

from SCHAUDT

reduces auxiliary

cycles

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

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

FURTHER INFORMATION

base comprises supplier companies of the automotive industry. “The attractive

price-performance ratio makes the product very popular with our customers. In

order for this to continue in the

future, we are continuously de-

veloping the swivel-in spindle

further,” says Mavro.

cycles are very short as well, because

the machines can be retrofi tted quickly.

Thereby, suppliers of the automobile

industry are able to produce camshafts

for sports vehicles on one day and cam-

shafts for a top-of-the-range model on

the next. Furthermore, the double swiv-

el-in spindle from SCHAUDT allows for

relatively cost-effi cient production. “In

order to achieve the same effect without

our technology, you would need two B

axes within the machine. Our swivel-in

spindle costs only a third by compari-

son,” explains Mavro. Another advan-

tage is the high rigidity of the spindle

which allows an output of approx. 30

kilowatts during operation. Since the

variant with two grinding spindles has

been available for SCHAUDT machines,

the sales fi gures for the CamGrind series

have doubled. Over the course of the

last few months, the company has sold

machines to customers all over the

world. First and foremost, the customer

L_S.38-39_Schaudt_E.indd 39 19.10.11 18:56

40 MOTION 02/11


growth rates of more than ten percent has bestowed the nickname “Tiger of the

Bosphorus” on the nation which lies between occident and orient. Amongst the

G20 states, i.e. the 20 largest national economies of the world, Turkey can be found

in the 17th spot. Except for China, there is currently no other nation in this group

of states which can record similar growth fi gures. Along with tourism, the me-

chanical engineering sector is especially booming.

Dynamic machine market

According to information provided by the Turkish Association of Machine Manu-

facturers Makina Imalatcilaro Birligi (MIB) and Germany Trade Invest, machines in

the fi eld of investment goods with a total value of 31.3 billion US dollars were

Europe under its feet, Asia before its

eyes: Istanbul is the only city of the

world that is located on two continents.

The vibrant megacity on the Istanbul

Strait represents the new Turkey, bring-

ing in line tradition and the modern age.

The economic development of the coun-

try with a wealth of cultural riches is

impressive. A considerable boom with

COUNTRY SPECIAL

Boom region in the Middle EastThe Turkish economy has registered record growth. The fi eld of mechanical engineer-ing in this country is one of the most notable winners.

The blue mosque: the house of

worship with six minarets is a

must for Istanbul visitors

TURKEY IN A NUTSHELL

Population: 73.7 million (2011)

Capital: Ankara

Currency: Turkish lira

GDP: $735.8 billion

(2010, nominal)

GDP per capita: $ 9,984 (2009)

National language: Turkish

Surface area: 783.562 km²

National holiday: 29 October:

Republic Day

Istanbul

Ankara

L_S.40-42_Tuerkei_E.indd 40 25.10.11 10:48

41MOTION 02/11

Two branch offi ces, all brands

In this prosperous environment, the

SCHLEIFRING group is cooperating in

partnerships with renowned Turkish

market experts. The company CELIK

MAKINA has specialised in machines in

the fi eld of tool grinding and represents

the brands WALTER and EWAG. At

FORM MAKINA, approx. 80 experts

work in the fi elds of cylindrical and sur-

face grinding – and represent the brands

STUDER, SCHAUDT, MIKROSA,

MÄGERLE, BLOHM, and JUNG. FORM

MAKINA is supported by Atilla Aydin,

grossed in 2010. This corresponds to a

plus of approx. 33 percent when com-

pared to the previous year.

This makes the industry one of the win-

ners of the most recent economic up-

swing after the fi nancial market crisis of

2008/2009. Furthermore, MIB forecasts

a further high need for machine tools for

the medium term. One reason for this

development can be attributed to the

relatively old machinery in Turkey. Com-

panies are being expanded and modern-

ised across the country. The demand is

extremely high in the automobile indus-

try and in the fi elds of entertainment and

household electronics. Furthermore, it

can be observed that the demand in-

creasingly focuses on high-tech equip-

ment on the basis of the increasing qual-

ity requirements.

Moreover, a growth strategy of the Turk-

ish government has positive effects on

this development. The objective is to

achieve an export volume of 100 billion

US dollars before 2023, said Marcus

Knupp from Germany Trade & Invest in

Istanbul. To do so, “fi nancing options

shall be improved, the qualifi cation basis

shall be increased, and research and

development in the fi eld of mechanical

engineering shall be supported.”

Traditional bazaar: tourism is still one of the most

important economic sectors

Contact person on site: Atilla Aydin, Area Sales Manager of Fritz Studer AG (left) with Sinan Calik, Sales

Coordinator of FORM MAKINA, at the Tatef trade fair

Bridging the gap: the Istanbul Strait divides Istanbul

into a European and an Asian part

Ruins of Ephesus: with the Temple of Artemis, the city accommodated one of the seven wonders of the world

RATE GROWTH

Source: Germany Trade and Invest, May 20101

35

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Development of Turkish industrial production in 2010 compared to the previous year 2009 (in percent)

L_S.40-42_Tuerkei_E.indd 41 25.10.11 10:48


42 MOTION 02/11

The other face of Turkey: skiing regions offer downhill fun from December to April. The ski slopes are partially

located more than 4,000 metres high; some slopes are located near the coasts

Area Sales Manager of Fritz Studer AG.

He has his offi ce in the Istanbul head-

quarters of the branch offi ce.

Aydin appreciates the metropolis both

from a professional and a private point

of view - on the one hand, because the

majority of Turkish mechanical engi-

neering companies can be found in the

north-west of Turkey around Istanbul,

Bursa, and Kocaeli; on the other hand,

the 47 year old enjoys living on the Is-

tanbul Strait.

SMALL BUSINESS ETIQUET TE MANUAL

That’s the way it goes in Turkey

People making a business trip to Turkey

should be aware of some conventions.

Dress code: In Turkey, classy clothes and

a well-groomed appearance are obliga-

tory for business meetings. Casual clothes

are quickly interpreted as a lack of appre-

ciation towards the dialogue partner.

Salutation: The most senior participant

of a meeting must always be greeted fi rst.

The salutation is by handshake and, while

doing so, you must look into the other’s

eyes. If Turks have known and appreci-

ated their dialogue partner for a long time,

this may result in an embrace or an ami-

cable kiss on the cheek. Caution: women

wearing head scarves do not normally

want to be touched by men.

Small talk: In Turkey, it is recommend-

able to carry a large number of business

cards with you, because they are distrib-

uted extensively. Regarding their dia-

logue partners, Turks want to know with

whom they are dealing and, therefore,

also talk about private matters. People

who take the time to establish a personal

relationship before negotiations have

higher chances of success.

Eating and drinking: Normally, the host

company will pay the bill. Any attempt of

the visitor to pay the restaurant bill is un-

welcome. If the mobile phone rings while

sitting at the table, it is natural to take the

call. By contrast, it is deemed rude to wipe

one’s nose while sitting at the table.

Don’ts: During the fasting month of Ra-

madan, visitors should try to avoid eating

or drinking in the presence of natives dur-

ing the day.

+ + + w w w . f o r m c n c . c o m . t r + + +

w w w . c e l i k m a k i n a . c o m + + +

FURTHER INFORMATION

Motley metropolis

“Istanbul is the city of dreams. All kinds of cultures with different religions have lived

in this city and designed it,” says Aydin who studied industrial economics in Turkey.

Amongst other things, this resulted in popular buildings such as the blue mosque or

the Topkapi palace. Furthermore, the large number of squares and bazaars are lively

places. With more than 13 million inhabitants, Istanbul is one of the most heavily

populated cities in the world. “On average, every family has two vehicles,” says

Aydin. “The hustle and bustle is sometimes exhausting, but always very exciting. For

example, you can cross the Istanbul Strait in a few minutes by means of bridges, but

that may also take three hours during the evening rush hour.” Aydin feels the boom

in his home country. “The Turkish machine

market is developing very quickly.” MIB fore-

casts a plus of approx. 20 percent for this mar-

ket for 2011 alone.

Recep Tayyip Erdogan: The Prime Minister

has ruled the country since 2003. In June

2011 he was re-elected

L_S.40-42_Tuerkei_E.indd 42 25.10.11 10:48

43MOTION 02/11

For coolant pumps, actuation via frequency converters allows for ideal adjust-

ment via the CNC control system. This way, specifi c pressure stages can be

implemented and energy saved for certain grinding processes. Traditionally, this

was implemented by means of a ball cock or a bypass valve. However, if a coarse

grinding wheel is used for pre-grinding purposes, effi cient cooling is required. If

another grinding process is implemented

with a fi ne grinding wheel in the same clamp-

ing operation, too strong a cooling lubrication

may have adverse effects on the geometric

fi nal result. The advantages of this control: a

perfect cooling lubrication for rough grinding,

no fl oating of the grinding wheel during fi ne

grinding, and lower heat input into the cooling

lubricant. This results in a reduced energy

consumption of the pump and the coolant

cooler, because less energy must be with-

drawn from the cooling lubricant.

The alternative for manually guided

profi le projectors and pre-adjust-

ment devices: using the WALTER Easy-

Check software, tool measurement

and profi le detection are implemented

digitally and automatically via mouse

click. Without time-consuming pre-

paratory work, the CNC axes are con-

trolled completely electronically on

the screen with the highest positioning

accuracy and speed. Automatic profi le

detection is implemented in an inter-

active, fully automatic, and highly pre-

cise manner. Step by step the indi-

vidual details or the entire tool contour

can be collected with the different pro-

fi le detection functions. Mechanical

effects on the axes by means of han-

dles or a single-hand guidance during

tool measurement and profi le detec-

tion procedures have gone the way of

the dodo. The entire projector mode

has been newly defi ned. The macro

function makes it possible to accept

measurement functions. The “trained”

measuring procedure is stored as a

fi le. Identical parts are measured

quickly and effi ciently.

Clever cooling: exemplary characteristic curve

for a coolant pump with fi xed frequencies

WALTER

EasyCheck:

innovative

mouse function

PUMPS

Advantageous frequency converter mode

TOOL MEASURING TECHNOLOGY

Fully-automatic profi le detection

SHOE GRINDING

Universal shoe grinding attachment

NEWS TO USE

Practical production tipsThe little things simplify the day-to-day grinding business – for example, products such as the universal shoe grinding attachment from STUDER, the WALTER EasyCheck measurement soft-ware, and the frequency converter options for coolant pumps on BLOHM und JUNG machines.

Today, roller bearings are not only produced in large-scale series on single-

purpose machines – there is an increasing demand for special bearings

and, particularly, precision-bearings “just in time” in smaller lot sizes. Therefore

there is an increasing focus on short change-over times and a fl exible produc-

tion. With its broad machine portfolio, Studer AG is prepared for this. Depend-

ing on the processing assignment, the

corresponding machine model is selected

and equipped with a universal shoe grind-

ing attachment. The unit developed in

cooperation with the Internal Grinding

competence centre in Biel, Switzerland, is

designed for a broad fi eld of application

and can be used on pure internal and ex-

ternal grinding machines, as well as on

universal grinding [email protected]

[email protected]

STUDER shoe grinding attachment:

implemented on an S31 and a CT450 with

WIB AG in Bulle (Switzerland)

christoph.ehrler@

walter-machines.com

WALTER

EasyCheck:

innovative

mouse function

180

160

140

120

100

80

60

40

20

020 40 60 80 100 120 l/min

Tool A

50Hz

m

Tool B

Tool C

Fixedly-program-mable pressure stages (fi xed frequencies)

45Hz

40Hz

33Hz

25Hz

17Hz

So

urc

e: B

rin

kman

n

L_S.43_News to use_E.indd 43 19.10.11 18:59

Körber Schleifring Machinery

(Shanghai) Co. Ltd.

1128, Tai Shun RoadAnting TownShanghai Jiading District 201814, ChinaPhone +86-21-395873-33Fax [email protected]


(Shanghai) Co. Ltd.

Beijing Branch Offi ce

Room 202, Building 18, Tower B, Universal Business Park,No.10 Jiuxianqiao Road, Chaoyang DistrictBeijing 100015, ChinaPhone +86-10-659318-31Fax [email protected]


(Shanghai) Co. Ltd.

Wuxi Branch Offi ce

A-096 YangmingHi-Tech Industrial ParkWuxi Jiangsu 214024, ChinaPhone +86-510-854206-66Fax [email protected]


(Shanghai) Co. Ltd.

Chongqing Branch Offi ce

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


(Shanghai) Co. Ltd.

Guangzhou Branch Offi ce

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

United Grinding

Technologies Inc.

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

United Grinding

Technologies Inc.

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

Körber Schleifring GmbH

India Branch Offi ce

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

Mägerle AG Maschinenfabrik

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

Blohm Jung GmbH

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

Blohm Jung GmbH

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

Fritz Studer AG

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

Schaudt Mikrosa GmbH

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

StuderTEC K.K.

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

Walter Maschinenbau GmbH

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

Walter Machines

Asia Pacifi c Pte. Ltd.

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

Ewag AG

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

Walter Machines UK Ltd.

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

Walter Kurim s.r.o.

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

Walter Machines Italia Srl

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

Walter Japan K.K.

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

Walter Máquinas Ltda.

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

Körber Schleifring GmbH

Nagelsweg 33–35

20097 Hamburg

Germany

Phone +49-40-21107-03

Fax +49-40-21107-13

[email protected]

www.schleifring.net

SU

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L_S.44_Adressen_E.indd 44 19.10.11 18:59

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