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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:
NEEF + STUMME premium printing GmbH & Co. KG, Wit tingen
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
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-
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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]
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
T O O L S & T E C H N O LO GY
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
T O O L S & T E C H N O LO GY
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
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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
M O T I O N S & M O R E
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 + + +
M O T I O N S & M O R E
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
T O O L S & T E C H N O LO GY
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
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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
M O T I O N S & M O R E
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
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
T O O L S & T E C H N O LO GY
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
L_S.30-33_Studer Technology_E.indd 31 20.10.11 14:50
32
Full speed ahead: the
material is more resilient
than many grinders think
MOTION 02/11
T O O L S & T E C H N O LO GY
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
L_S.30-33_Studer Technology_E.indd 32 20.10.11 14:50
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
L_S.30-33_Studer Technology_E.indd 33 20.10.11 14:50
M O T I O N S & M O R E
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
L_S.34-37_Schulungen_E.indd 35 20.10.11 14:49
36 MOTION 02/11
M O T I O N S & M O R E
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
L_S.34-37_Schulungen_E.indd 36 20.10.11 14:49
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
L_S.34-37_Schulungen_E.indd 37 20.10.11 14:49
38 MOTION 02/11
T O O L S & T E C H N O LO GY
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
M A R K E T S & T R E N DS
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
30
25
20
15
10
5
0 8,1
B
ever
ages
20,3
R
ub
ber
an
d p
last
ic p
rod
uct
ion
27,2
E
lect
rica
l ap
plia
nce
s
12
,7 Te
xti
le in
du
stry
19,7
M
etal
pro
du
ctio
n
34
,9 C
om
pu
ter/
ente
rtai
nm
ent
elec
tro
nic
s
15
,9 C
hem
ical
ind
ust
ry
32
,6 M
ach
ines
an
d e
qu
ipm
ent
33
,3 M
oto
r ve
hic
les
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
M A R K E T S & T R E N DS
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.
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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]
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]
Körber Schleifring Machinery
(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]
Körber Schleifring Machinery
(Shanghai) Co. Ltd.
Wuxi Branch Offi ce
A-096 YangmingHi-Tech Industrial ParkWuxi Jiangsu 214024, ChinaPhone +86-510-854206-66Fax [email protected]
Körber Schleifring Machinery
(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]
Körber Schleifring Machinery
(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
www.schleifring.net
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