Sharpening specialist Vollmer used last month’s EMO exhibition in Hanover to present automated grinding, eroding and laser machines for manufacturing tools made of ultra-hard cutting materials such as PCD, CBN and carbide.

This year’s product highlight on the Vollmer stand was the VHybrid 260, which can grind and erode tools up to 100% in a single set-up. The VHybrid 260 features multi-level machining realised via two vertically arranged spindles, where the lower spindle is for both grinding and EDM. With the new V@dison booster solution, the VHybrid 260 achieves a surface quality of up to 0.05 µm Ra when eroding PCD tools.

Thanks to the digital application, it is possible to integrate EDMinto tool production as a complete manufacturing process. According to Vollmer, with the Vpulse EDM generator, users can even producemicro-tools with diameters of 0.5mm and smaller with high precision, performance and surface quality. High accuracy is deliverable via the integrated ‘Laser Check’ measuring system, which achieves required tolerances of ±2µm in fully automatic closed-loop machining.

Also in spotlight at EMO was the Vollmer VGrind 360S tool grinder, which again features the concept of multi-level machining. At the show, Vollmer focused on the machining of CBN tools and how tool manufacturers can use the machine to configure and equip their production, regardless of whether they manufacture special tools or produce tools in high volumes.

Using appropriate automation such as the new HP 170 pallet magazine, the HPR 250 free-arm robot or HC4 chain magazine, the VGrind 360S is suitable for unmanned machining around the clock. With the HP 170, customers can also opt to integrate optical detection of the cooling channels.
For further information www.vollmer-group.com

With its deephone series, Gehring Technologies offers horizontal honing machines for a wide range of large components. At EMO 2023 in Hanover last month, the company presented new developments and features in this segment that enable the more cost-effective execution of demanding and complex machining processes.

“At this year’s EMO, we wanted to show potential customers that we can offer a complete package for honing large workpieces from a single source with our machines, tools and process know-how,” emphasises Marcell Wardin, director ofsales andmarketing. “This package includes a wide range of precision tube components, including cylinder liners for the hydraulic industry, aircraft landing legs, ingot moulds and even radio masts.”

Gehring has developed the deephone machine series for precisely these applications. Stroke lengths range from 2000 to 10,000 mm, while internal machining is possible up to 1200 mm and external machining up to 300 mm.

“An important feature of these machines is their flexibility,” adds Wardin. Indeed, a three-stage gearbox makes it possible to machine a wide variety of workpieces on one machine. Depending on the size of the workpiece or the removal rate, the power requirement changes. The three-stage gearbox provides the necessary adjustment. Without such a component, it may be necessary to distribute different workpieces among several machines or to re-clamp demanding workpieces. With a complete package from a single source, manufacturers can reduce their investment costs.

Gehring also offers tooling innovations. In principle, all tools are adaptable to the company’s deephone machines. Nevertheless, Gehring has a new DH tool series,a special feature of which is their internal cooling system. The company suggests these tools can cut machining time by 20-30% and reduce the need for coolant.
For further information www.gehring-group.com

The United Grinding stand at the EMO exhibition in Hanover last month featured a host of Walter machines and technologies for effective and efficient tool and insert grinding/erosion. In particular, parent group United Grinding’s CORE (Customer Oriented REvolution) hardware/software architecture and Walter’s Laser Contour Check non-contact tool measurement development, shared centre stage.

CORE architecture embraces the digital age by offering intuitive operation that facilitates machine set-up, operation, networking and maintenance. Underpinning this ethos is ‘work simplification in production’ topave the way for a new generation of machine tools which fully embrace the digital age.

Laser Contour Check is now optional on all Walter Helitronic tool grinding and erosion machines. This featureensures high precision and fast in-process measurement of tool parameters using blue laser technology in conjunction with process intelligence to measure various features on cylindrical tools from 1 to 52 mm diameter. Compensation for any deviations takes place during the machining process.

Laser Contour Check’s analogue laser beam measures a tool’s entire contour rather than just specific points, as with tactile or digital methods. Laser technology also avoids possible damage to the tool’s cutting edges, as well as measuring errors that could occur due to probe tip wear during tactile measuring routines. It is possible to integrate the measuring system directly into the machine’s working area, so it moves into position when required.

At EMO, visitors saw both CORE and Laser Contour Check on Walter’s Helitronic Mini Plus and Helitronic Micro tool grinders.While the former produces tools of 1 to 16 mm diameter and up to 255 mm long, and re-grinds tools of 3 to 100 mm diameter, the latter processes tools from 0.1 to 12.7 mm diameter and 220 mm long.
For further information www.walter-machines.com/en

The serial production of large gears requires a high level of quality, excellence and continuity in production. Particular emphasis is on maximising the synergy between the grinding machine, grinding process and grinding wheel. After several successful trials on various Klingelnberg Höfler Rapid series grinding machines carried out at various customer production facilities, Krebs & Riedel has received several significant orders for grinding large gears and introduced its new premium grinding wheels with high process reliability.

Krebs & Riedel is a major manufacturer of grinding wheels for gear grinding in the automotive and EV sector. Now, with its new Blue Moon TZ premium product range, the company is expanding into other sectors that require large gears, such as wind turbines.

“In some tests, the material removal rate (Q’w) was more than 30 mm³/mm,” says Sigurd De Ridder, senior application engineer at Krebs & Riedel, who conducts trials and process optimisation for customers worldwide. “Precision-shaped abrasive grains are state of the art today. Blue Moon TZ is self-sharpening, very sharp-edged, microcrystalline and has an elongated trapezoidal shape.”

According to Krebs & Riedel, the homogeneous pore structure of Blue Moon TZ contributes to an extreme improvement in the entire cooling system during grinding. Due to the open structure, coolant immediately floods the whole grinding wheel. Even with extreme material removal rate, the coolant transports chip away from the contact surface, avoiding heat input that could lead to thermal damage of the gear.

On average, tests on Klingelnberg Höfler Rapid 2500 machines showed the following grinding results: a cooler grind and a longer tool life, combined with up to 20% faster grinding time compared with standard grinding wheels. In dressing tests, the average result showed 20% longer dressing intervals and 30% less infeed.
For further information www.krebs-riedel.com