Hard coating of brake discs using laser welding

The EURO 7 standard will immensely change the automotive industry: for the first time, not only emissions from combustion engines will be regulated, but also the abrasion of brakes, among other things. The initial conclusion is that the particulate matter produced by many models must be significantly reduced. As a result, OEMs and suppliers are looking for a new solution for the braking system, with coated brake discs currently proving to be the ideal solution for the task.

So how can the various coating systems be applied reliably and efficiently in the context of high-volume production? EMAG offers the answer to this question: a complete solution ready for series production for the coating of brake discs by laser deposition welding, which has already proven itself in production.

The ELC 450 LMD is a machine solution from EMAG that is characterised by its modularity and flexibility. The basic idea behind the ELC 450 LMD is the use of process modules that can be combined and expanded according to customer requirements. The basic version, the ELC 450 LMD, has one process module. The ELC 450 DUO LMD is equipped with two process modules, while the ELC 450 TRIO LMD, as the name suggests, uses three process modules.

These modular machine concepts make it possible to optimally meet customer requirements in terms of shift structure and productivity. This then determines the choice of machine configuration. The ELC 450 LMD can realize both one-shift and two-shift systems. The combination of laser power and application rate determines the most suitable machine concept for the respective application.

More information www.emag.com

Helical component manufacturer chooses Zenith

UK-based PTG Holroyd Precision is to supply one of its ultra-precise Zenith 400 helical profile grinding machines to a Chinese manufacturer of helical components. Developed to precision-grind components weighing up to 700 kg and measuring up to 420 mm in diameter, 2.2 m in length and with a maximum 100 mm profile depth, the Zenith 400 combines high stock removal rates with aggressive semi-finishing. It offers production rates and accuracies tailored to the most demanding of manufacturing strategies.

Scheduled for installation at the Chinese company’s Chongqing-based production facility this summer, the Zenith 400 is equipped with PTG Holroyd’s proprietary dual grinding wheel system. This capability will enable operators to use either a 500 mm vitrified, dressable aluminium oxide grinding wheel for exceptional versatility in production strategies and product development, or diamond-hard plated CBN roughing and finishing wheels for cost-effective volume production.

“With the advantage of two grinding wheels, our customer will be able to complete both rough-grinding and finish-grinding in one seamless operation,” says PTG Holroyd Precision’s sales director Mark Curran. “By using CBN grinding wheels for both grinding processes, they will benefit from significantly reduced cycle times and improved heat dissipation. Thanks to the greater resistance of CBN, the customer will also enjoy extended wheel life, with no need for dressing, even at high stock removal rates.”

He adds: “In addition to the Zenith 400’s well-proven capabilities, its dual grinding wheel capability was clearly a major attraction to the customer in view of the efficiencies this will bring to their production processes.”

More information www.holroyd.com

Mirka launches high-performance grinding wheels

Mirka is expanding its product portfolio with the launch of the Mirka Cafro Ultra-Flute grinding wheel range for the precision grinding of solid-tungsten carbide tools. The new product line offers users a selection of durable and precise grinding wheels, engineered to withstand the demands of large-scale production runs.

Cafro Ultra-Flute is engineered as a single-piece construction and features an abrasive rim that has a porous structure that optimises the power transfer from the grinding machine to the material. This design ensures high stock removal rates in less time, which leads to an increase in the overall efficiency of the process, reports Mirka.

The product has been developed with durability at the forefront of the design process, highlighted by its edge retention that aids in the delivery of fast, efficient and consistent performance. Cafro Ultra-Flute grinding wheels also help increase productivity as there is less downtime due to the dressing intervals being longer.

The range also provides the user with a quiet operation, no vibrations when in use and stable power absorption for reduced energy consumption during the time it is working. Additionally, when paired with automatic tool loaders, it performs at an optimal level and leaves a consistently fine surface finish.

Kevin Jackson, business development manager – superabrasives and automation at Mirka UK, says: “With the launch of our Cafro Ultra-Flute, we’re providing tool manufacturers with a cutting-edge solution that enhances productivity and reduces costs. This new grinding wheel range also highlights our commitment to providing high-quality, performance-driven grinding solutions that will be an asset to the customer from the first use to the last.”

More information www.mirka.com

Indicating the way to sustainable manufacturing

As the UK distributor for Rosa Ermando’s Rosa GrindTech and Favretto GrindTech grinding machines, Master Abrasives is introducing two key themes that are central to the future of manufacturing: energy-saving solutions and sustainability.

In the face of today’s complex economic challenges, Davide Lucca, CEO of Rosa Ermando, believes that businesses must leverage digitalisation, energy efficiency and sustainability to gain a competitive edge.

“European machine manufacturers have excelled at designing and producing high-quality machinery,” he says. “However, to remain competitive on a global scale, we must go beyond just manufacturing products. We need to focus on integrated solutions that combine innovative machinery, services, and processes.”

Master Abrasives shares this vision and excited to bring these innovative solutions to the UK market, highlighting how Rosa and Favretto’s technology can drive both operational efficiency and sustainability.

One of the stand-out features of Rosa and Favretto machines is their focus on energy saving – an essential consideration for businesses aiming to reduce operational costs and their environmental impact. At the BI-MU exhibition in Milan last year, Rosa Ermando presented an advanced energy management system that is now available on all Rosa GrindTech and Favretto GrindTech machines. This new feature allows users to measure energy consumption in real-time, providing detailed insights into energy absorption across different components and processing steps.

“Our new system not only tracks overall energy usage but also enables differentiation by monitoring the energy consumption of specific parts of the machine,” says Lucca. “The next step is to modulate machine functions based on actual energy requirements, which helps optimise consumption and enhance overall system efficiency.”

More information www.master-abrasives.co.uk

Grinding Hub back in 2026 for the third time

Everything relating to grinding technology for experts from all over the world – that is what GrindingHub will offer in Stuttgart from 5 to 8 May 2026. After two successful editions, the organiser VDW (German Machine Tool Builders’ Association) will continue the trade fair’s success story in co-operation with Messe Stuttgart and the Grinding Conference.

Dr Markus Heering, managing director of the VDW, says: “GrindingHub has become established as the central hub for the grinding technology industry. The energy and commitment of every participant in the previous editions of the trade fair were overwhelming.”

Marie-Sophie Maier, managing director of Adelbert Haas GmbH, has been an exhibitor from the very beginning: “This trade fair is the ideal platform for our company: internationally oriented, technologically leading and tailored precisely to our industry. At GrindingHub we meet the right trendsetters with whom we can jointly shape the future of grinding technology.”

Markus Kiffe, managing director of Kiffe Engineering GmbH and a visitor to GrindingHub 2024, shares this enthusiasm: “We’ll definitely come back again because you always see interesting things here and obtain exciting ideas, establish numerous contacts and hold a large number of discussions.”

In 2026 GrindingHub will again feature a wide range of grinding machines, abrasives, software tools, process peripherals, and measuring and test systems. Companies wanting to exhibit their innovations and products at the leading trade fair for grinding technology can now register online.

Heering concludes: “It’s always inspiring to see how the industry – despite and even because of the economically challenging times – comes together and plays a mutually supporting role. We’re convinced that GrindingHub 2026 will again be a great success.”

More information www.grindinghub.de/en