GrindingHub, a trade fair for grinding technology, will be held in Stuttgart May 17-20, 2022, and will provide a platform for finishing and superfinishing.

Finishing and superfinishing, lapping, honing, and vibratory grinding: an impressive range of manufacturing processes can be used to create a final surface finish. The proverbial finishing touch influences the functional behavior of workpieces and components, yielding unique characteristics and competitive advantages. GrindingHub, a trade fair for grinding technology, will be held in Stuttgart May 17-20, 2022, and will provide a platform for finishing and superfinishing.

Companies looking for specialists to help them move into superfinishing It took Uli Lars Bögelein “less than ten seconds” to make up his mind to exhibit at GrindingHub. The entire industry is certain to benefit from the trade show, says the managing director of Stähli Läpp-Technik GmbH, based near Stuttgart. Founded over 40 years ago as a sales company for flat honing, lapping and polishing machines produced by the Swiss Stähli Group, Stähli Läpp-Technik GmbH is now part of the group. Its core competences include engineering, sales, and contract processing. The latter represents an ideal way into superfinishing – and to much more besides, as Bögelein makes clear.

The Stähli Managing Director describes the three main groups of users who contact him. These come primarily from the automotive and electrical industries, medical technology, mechanical engineering, and the optical industry. The first group of users is not (yet) concerned about the investment costs for both the 2- and 3-wheel flat honing machines and the 1-wheel lapping and polishing machines because their production quantities are too low. Then comes the second group which needs high, if not extremely high, quantities, but which "specifically wants to avoid taking care of these processes, and all they involve, within their own company". Lapping machines in particular bring their own challenges and do not fit into every production operation, Bögelein admits. It is a demanding process which still requires a lot of manual work – and specially trained and highly motivated employees.

Finally, there is a third group of users. These run test series at Stähli. Until the series is working smoothly, they would first like to familiarize themselves with the process and the machine, and take advantage of the service and know-how offered by Stähli Läpp-Technik. The company also offers the entire range of consumables and accessories for this, including everything from CBN wheels and diamond suspensions through to testing equipment. Uli Bögelein notes that trade fairs are very important and are often used for making the first contact. Visitors come with drawings and workpieces, but also specific machine inquiries, and to have the technology explained to them. Specific technological know-how is required in cases involving manufacturing tolerances in the submicrometer range and filigree functional surfaces.

Drivers of industry development According to Thomas Harter, product manager at Supfina Grieshaber, based in Wolfach in the Black Forest, companies’ increased motivation to concern themselves with surface quality and finishing and superfinishing processes stems from clearly identifiable "development drivers.” Supfina has many years of experience in the field of superfinishing and grinding. It develops machines and conducts related research – and will also be exhibiting at GrindingHub.

Harter cites examples from the automotive technology field. For example, the expected legal regulations for Euro 7 and the associated reduction in particulate matter are driving the development of the brake disc market. Future brake discs, he says, will probably feature hard coatings that are difficult to machine. As a development partner, Supfina takes care of developing the process for grinding the coated brake discs. The know-how is used in the development of the entire process chain, ultimately enabling cost-effective production of the brake disc.

e-mobility is also placing new demands on superfinishing. Future-proof solutions are needed to reduce noise in the powertrain, the steering or when adjusting seats and windows inside the vehicle. For example, Supfina has developed a machine series for the economical production of low-noise roller bearings.

Defining specific surface parameters Dr. André Wagner, Head of Grinding Technology at Hermes Schleifmittel, Hamburg, makes clear just how much the demands on surface quality are changing and how important precise coordination with customers is becoming as a result. While some processes, such as high-performance steel cutting, are optimized primarily for productivity and cost-effectiveness, processes such as gear grinding must yield high workpiece quality, says Wagner. The goal of reducing surface roughness to a minimum, which was common in the past, is increasingly being replaced by that of achieving specific surface characteristics. However, the selection and definition of the desired surface properties depends to a great extent on the particular gear application and the specific goal. "Effective communication between the customers and the grinding tool manufacturer is therefore essential," Wagner emphasizes. The general machine conditions, the quality requirements for the component being produced and also the productivity of the process have to be clearly defined and coordinated in advance. According to Wagner, ideal process results can only be obtained by setting precise objectives and designing the grinding process on an application-specific basis. In the case of gears, for example, this would ensure maximum efficiency of the transmission and reduce noise emissions, which are crucial for electrically driven vehicles. All process-defining parameters such as machine environment and cooling lubricant supply must be taken into account when selecting and designing suitable grinding tools. "High-performance tools aren’t always necessary. In many cases, less exacting specifications may also suffice if the process as a whole is designed correctly," says André Wagner.

Scientists focusing on process chains Finishing and superfinishing processes can play a role in creating unique workpieces. The Institute for Machine Tools and Factory Management (IWF) at the Technical University of Berlin believes that “...there is a noticeable trend toward manufacturing individualized products in small batches. This is giving rise to an increasing need for manufacturing processes that can be adapted to changing product requirements." Research is being conducted into robot-guided machining processes for finishing and superfinishing by the Institute. "Robot-guided machining processes can be used on many different components, especially in combination with flexible or freely movable tools, as in abrasive brushing, belt grinding or vibratory grinding," explains Institute Director Prof. Eckart Uhlmann. "Honing processes that are conventionally performed on rigid machine tools can also be taken care of using robot-guided honing tools to rework bores in different positions." Uhlmann, who is also a member of the WGP (German Academic Association for Production Technology), believes that the main advantage of using a robot as a universal processing machine is that it allows the different processing steps to be linked flexibly. Process chains can then be adapted to the respective component requirements with little effort.

Interest in the research proves that greater use is expected to be made of innovative finishing and superfinishing processes in the future. However, they are still fraught with problems for many companies. It is true that the industry offers both technologically advanced machines and tools as well as extensive specialized knowledge for creating surfaces of tribologically stressed functional surfaces. Yet the special machines are too expensive for small and medium-sized companies and for relatively small or medium batch sizes, the automation is complex and knowledge about cause-effect relationships is limited to specialists. Trade shows such as GrindingHub offer an opportunity to showcase machines, tools, processes, and work results.

Don't miss out on the Jan. 5, 2022 webinar featuring Terry Wohlers discussing the latest trends in additive manufacturing. Registration is open now and free.

The breadth of AM applications is mind-bending to many. Few manufacturing processes cut across so many industrial sectors. Imagine producing a sensor of a few millimeters and a bridge of many meters using a similar successive layering process. This breadth has led to the development of hundreds of startup companies. In the future, it will be thousands.

Registration is free for the Wed., Jan 5, 2022 webinar happening at 11AM ET.

Terry Wohlers is the head of additive manufacturing market intelligence. Wohlers has provided consulting assistance to more than 280 organizations in 27 countries, as well as to nearly 200 companies in the investment community. He has authored 440 books, articles, and technical papers and has given 170 keynote presentations on six continents. Wohlers served as a featured speaker in events held at the White House in 2012 and 2014 and has appeared on many television and radio news programs. He is a principal author of the Wohlers Report, the undisputed industry-leading report on additive manufacturing and 3D printing worldwide for 26 years. 

Leading developer of manufacturing automation systems expands footprint in life sciences industry with new acquisition of Oakland-based machine building firm.

MiQ Partners, an intelligent automation firm with operational facilities in Carlsbad, California and West Chester, Ohio announces the purchase of CKC Engineering, a precision automation machine building company in Oakland, California. This acquisition is designed to increase local services and support for existing clients located in Northern California and the Pacific Northwest, and further capacity to serve additional clients across the life sciences sector and other industries.

With the addition of a third facility, MiQ's total capacity is 155,000ft2, allocated as follows:

CKC Engineering brings complimentary expertise in automation solutions for the life sciences industry, providing custom automation machines for global brands such as Baxter, Medtronic, and Boston Scientific. Specialty services they bring to MiQ Partners include aseptic syringe filling, vertical farming manufacturing solutions, and packaging for medicinal products.

"The addition of CKC Engineering helps to complete the vision of MiQ Partners to be a single source for comprehensive automation solutions for life sciences in California," says Olaf Tessarzyk. "Our Carlsbad facility has doubled in size, helping to contribute to the burgeoning growth of life sciences manufacturing in California. This acquisition now allows us to partner with companies across the entire west coast, helping to increase efficiencies for a wide variety of leaders in both the life sciences and other industries. MiQ and CKC represent proven engineers with innovative minds that are driving unparalleled outcomes for clients nationwide."

Founded in 2005, CKC Engineering brings a team of 13 highly accomplished automation engineers with proven entrepreneurial experience to MiQ Partners, increasing the company's total staff to nearly 150 professionals nationwide.

MiQ Partners was founded in 2019 when TSS Technologies and R&3D Automation were acquired by Resilience Capital Partners, a private equity firm in Cleveland, Ohio. The businesses were integrated to form MiQ Partners, a new platform focusing on intelligent automation services across life sciences, aerospace, industrial and CPG industries offering custom solutions, automation machines, contract manufacturing, build to print, contract machining, and engineering design services.

"This acquisition is a major milestone for MiQ's vision to become the dominant provider of custom automation solutions in manufacturing across industries, helping move companies and economies forward as our nation ramps up production for critical products," says Ki Mixon, a partner at Resilience Capital. "We at Resilience are pleased with the progress MIQ is making as a business and the impact this highly accomplished team is having on the production goals of its clients nationwide."

Although 2020 closed out unlike anything in years, medical device manufacturers anticipate growth and stability to replace 2020’s disruptions and chaos.

Though vaccinations began in late 2020, they’ll have a bigger impact this year and will push medical manufacturing and the world toward a new normal. In achieving herd immunity, McKinsey & Co. estimates the U.S could complete inoculations by Q3 or Q4 of 2021.

Analysts from Oxford Economics note that manufacturing remained stable at the end of 2020, with the ISM Manufacturing index rising for seven consecutive months to a new recovery high of 60.7 in December. New production orders signal solid future activity, and inventories rose for a third straight month. Looking ahead, evolving recovery dynamics could cause factory activity growth to slow in 2021. Potential headwinds include the virus’ recent resurgence, slower economic recovery, and ongoing supply chain disruptions.

Read the full article now!

A common aspect of most manufacturing processes is to shape components by removing chips from materials surface. Now, researchers from Aarhus University have experimented to find the perfect cutting process.

Worn-out industrial milling tools and damaged materials cost the manufacturing industry billions each year.

In manufacturing processes, components are shaped by removing chips from a bulk material, but a clear understanding of what factors control the size and shape of removed chips has remained elusive, limiting the manufacturing sector to incremental advancement based on trial-and-error approaches.

Making a perfect cut every time is desirable, and now researchers at Aarhus University have modelled and experimented their way to solve the long-standing challenge of finding a perfect cutting process that minimizes tool wear and optimizes surface finish.

"We have developed a simple analytical model that can predict the mechanism for chip formation and its transition for almost every material. The model reveals the existence of a critical cutting depth as a function of material properties, tool geometry and running conditions,” says Associate Professor Ramin Aghababaei who’s leading the project at Aarhus University.

The study has been published in the scientific journal Physical Review Letters and the research is part of the project Cutting-Edge.

“By testing on various plastic materials, we have found a critical cutting depth, below which we can remove long chips in a smooth and gradual way and above which short and irregularly-shaped chip formed in an abrupt manner,” says Aghababaei.

The associate professor points out that deviation from this critical cutting depth has a major impact on wear and tear of the tools used, on energy consumption, and on the final product finish.

"We will continue to develop the model, but tool industry can start using it already to design optimal cutting tools,” he says.

The research forms part of the Grand Solutions project, Cutting-Edge, which aims to improve the performance of cutting tools for stainless steel processing. The project is being funded by the Innovation Fund Denmark with DKK 7 mio.