02.2022
The UNITED GRINDING Group's
customer magazine

INTERVIEW
What can additive manufacturing do for machine tools?
INTERNATIONAL Worldwide at your service! UNITED GRINDING in facts and figures
IN-DEPTH
Knowledge transfer and fostering young talent go hand in handAlex Frauchiger ison the IRPD team,which is behindthe development of
IMPACT 4530

WHEN
LASERSDANCE
In the “Motion” report, you can experience how the IMPACT 4530
creates components as if by magic – as the world’s first industrially compatible
machine tool for additive manufacturing, “Made in Switzerland”.

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IN THIS EDITION OF MOTION,
YOU WILL FIND:

4
6
8
14
16
18

WELCOMECEO Stephan Nell on the importance of the world’s firstAM machine tool “Made in Switzerland”
A LOOK INSIDE …
... the intelligent SmartJet® cooling system, which is
produced using 3D printing processes

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NEWS
News from the UNITED GRINDING Group27

INNOVATION
A report from St. Gallen, where IRPD developed the
IMPACT 453 AM machine tool
IN DEPTH
A modern approach to knowledge transfer is becoming
increasingly important for the UNITED GRINDING Group

34

INSIDEAt UNITED GRINDING, people from many cultures work
together — which demands skilled HR managers

40

INTERVIEW
Innovation and Tradition: What potential does additive
manufacturing have for industry – and what happens toproven grinding processes? A discussion among experts

43

A DAY WITH …
... Kirsten Brinck: How the head of technology and herteam at BLOHM JUNG drive innovation
TOOLS & TECHNOLOGY
The revolutionary IMPACT 4530 AM machine tool from
IRPD; tool changer now available for the BLOHM
PLANOMAT XT; STUDER’s new S100 internal cylindrical
grinding machine; and WALTER’s new HELITRONICMINI PLUS tool grinding machine
INTERNATIONAL
An overview: How the UNITED GRINDING Group
provides customers with the top service worldwide
IDEAS
Why the industry needs better data
INTOUCH
The Motion calendar: Important shows and events

IMPRINTPUBLISHER United Grinding Group Management AG, Wankdorfallee 5, 3014 Bern, Switzerland OVERSIGHT Paul Kössl PUBLICATION MANAGER
Michèle Fahrni EDITOR-IN-CHIEF Michael Hopp (Responsible for purposes of press law) ART DIRECTION Tobias Zabell ACCOUNT MANAGER
Jutta Groen IMAGE EDITOR Thomas Balke AUTHORS Markus Huth (text manager), Ira Schroers, Prof. Philipp Gölzer (guest contributor)
LAYOUT Claudia Knye PRODUCTION Wym Korff PUBLISHER AND EDITORIAL ADDRESS JAHRESZEITEN VERLAG GmbH, Harvestehuder Weg 42,
20149 Hamburg, Germany READER SERVICE wym.korff.extern@jalag.de EXECUTIVE DIRECTORS Thomas Ganske, Sebastian Ganske,
Susan Molzow, Arne Bergmann, Peter Rensmann LITHO EINSATZ Creative Production GmbH & Co. KG, Hamburg, Germany
PRINTING Walstead Kraków, Poland
All brand names marked with ® are registered as basic trademarks in Switzerland or in Germany as a minimum and are therefore entitled to use the mark.

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Cover: Thomas Eugster; Photos: Thomas Eugster (2), Dennis Williamson, Natalie Bothur

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WELCOME“PROVEN AND INNOVATIVETECHNOLOGIES SUCH AS
GRINDING AND ADDITIVEMANUFACTURING CANCOMPLEMENT EACH OTHERPERFECTLY.”

DEAR READERS,The UNITED GRINDING Group looks back on over 100 years of
tradition in the development of high-quality machine tools. To
date, more than 150,000 systems have been delivered around theworld. This success is built on proven know-how and the ability
to innovate technologically. Our IMPACT 4530 from IRPD is theworld’s first industrial-grade 'Made in Switzerland’ machine tool
for additive manufacturing to reach the market, and customers
are already benefiting from the use of 3D metal printing processes
for quality components. In addition to surface, profile, cylindrical,
and tool grinding, eroding, and (laser) measurement, the UNITED
GRINDING Group is now also active in additive manufacturing.
The fact that proven and innovative technologies do not haveto compete with each other, but rather can complement eachother perfectly, can be seen in the report on IRPD in St. Gallen
on page 8 and in my conversation with Professor Markus Bambach
from the Advanced Manufacturing Lab at ETH Zurich on page 18.
The success of our customers is always our number one goal.
Around the world, the roughly 2,500 employees of the UNITED
GRINDING Group work to provide our customers with high-quality
systems, expert advice, and superb service. To find out how we canturn our motto “We are where you are” into reality, check out
our network of more than 20 locations around the world on page
34. Similarly, a modern approach to knowledge transfer is also becoming increasingly important in this age of skilled worker
shortages and digitalization. We highlight our strategy in the “In
Depth” section on page 14.

Stephan Nell,
CEO, UNITED GRINDING Group

Stephan Nell
CEO, UNITED GRINDING Group

PS: We conducted a reader survey as part of the last issue of “Motion.” The respondents indicated a high level of satisfaction with ourstories. As far as distribution channels are concerned, the preference for “Email with a link to download” as a PDF and “Continue as a
printed magazine” were roughly equal. By far the most requested topic is “Application of new technologies.” As such, I think that this“Motion” squarely aims to satisfy the needs of our readers.

Motion 02.2022

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UNITED GRINDING GROUP

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A LOOK INSIDEBLOHMJUNG

STUDERSCHAUDTMIKROSAWALTER

EWAG

IRPD

BETTER GRINDING WITH 3D PRINTING
The innovative SmartJet® nozzles, used here in the STUDER S31 cylindrical
grinding machine, demonstrate that grinding and additive manufacturing
complement each other perfectly. The nozzles, manufactured by IRPD
through a 3D printing process, deliver an improved coolant supply without
requiring a manual intervention by the operator. The machine control oversees the entire process. Thanks to additive manufacturing, the nozzles havea flow-optimized design and are automatically adjusted by the system.
The technology guarantees precise and reproducible cooling and produces a coherent coolant jet with a high exit velocity of up to 20 meters per second (3,937 sfpm). SmartJet® not only reduces set-up and process times (improved efficiency and productivity) for operators, but also reduces coolant
and energy consumption by up to half compared to conventional coolingmethods. With the SmartJet® nozzles as an example, it is clear that additive
manufacturing boosts both efficiency and sustainability when grinding.

Photo: David SchweizerMÄGERLE

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UNITED GRINDING GROUPNEWSGERMANYUSA

INTRODUCTION OF VERSALOAD
UNITED GRINDING NORTH AMERICA presented its newautomation cell for cylindrical grinding machines at IMTS
in Chicago. The loading system, known as versaLoad,is compatible with various STUDER cylindrical grinding
machines and can be flexibly integrated into a variety
of work processes. Thanks to its high-mix, low-volumeconcept, easy operation, strong mobility, and goodvalue for money, the system is also of interest to
smaller companies. A single versaLoad system canincrease productivity by up to a third.

WORLD INNOVATIONS AT THE
OPEN HOUSE IN TÜBINGEN
A STRONG STREAM OF CUSTOMERS visited the OpenHouse at WALTER in Tübingen. The system andsolution supplier for tool production used theevent to demonstrate the latest developments
in tool production and resharpening, live from
September 14 – 16. Two world premieres drew
extra attention: The HELITRONIC MINI PLUS CNC
tool grinding machine and the HELICHECK NANO
CNC measuring machine both set new standards
and accents in the production and quality
assurance of high-quality tools. The HELITRONIC
G 200 tool grinding machine presented at thisyear’s GrindingHub trade fair and the revolutionary
C.O.R.E. hardware and software architecture from
UNITED GRINDING were put to work in the demo
center to allow for up-close assessment.

SWITZERLAND

USAUNITED GRINDING
EXHIBITS AT IMTS
IN CHICAGOMORE THAN 120,000 VISITORS and over 1,000 young
professionals took part in SwissSkills 2022 in Bern.
From September 7 – 11, roughly 150 Swiss career
categories, ranging from the trades to industry andservices, were presented at the BERNEXPO site. It was
the biggest SwissSkills in history, the organizers report.
The exhibition covered roughly 110,000 square meters,
which corresponds to around 14 soccer fields. The
UNITED GRINDING Group presented its companies andserved as a sponsor at the event, which is aimed attrainees, young and experienced professionals, highschool students, parents, and teachers. The trade fairappearance was entirely in the hands of the trainees: A
core team of five trainees from MÄGERLE and STUDER
was responsible for the concept and implementation.

Photo: David Schweizer

THE UNITED GRINDING GROUP PRESENTED ITSLATEST PRODUCTS AND TECHNOLOGIES at theInternational Manufacturing Technology Show
(IMTS) in Chicago in September. Under the motto“To the Future”, the BLOHM PLANOMAT XT Essential
with tool changer and the WALTER HELICHECK PLUS withintegrated 3D sensor were on display for the first time inNorth America. C.O.R.E., a cross-brand hardware andsoftware architecture, was a focal point of the exhibition.
“After four years away from the IMTS, we were delighted toreturn to Chicago and see our customers again and topresent our latest innovations to the world,” said Markus
Stolmar, CEO of UNITED GRINDING North America.

STRONG PARTICIPATIONAT SWISS SKILLS 2022

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MÄGERLE

BLOHM

JUNG

STUDERSCHAUDTMIKROSAWALTER

EWAG

IRPD

SWITZERLANDSWITZERLAND

MODERNIZATION OF THE
APPRENTICE FACILITYSTUDER WINS UNITED
GRINDING CHAMPIONSHIPSTUDER HAS FURTHER MODERNIZED its
apprentice facility for polymechanics
trainees. This includes, for example,
a modern CNC lathe to enhance
training in the area of CNC partproduction. “Skilled workers are inespecially high demand for thisdiscipline, and we are delighted to
now be able to impart this competence
to the trainees,” said Roger Leuenberger,
head of vocational training at STUDER. The
expansion is part of the “Vocational training 2025”
project. One year earlier, the training workshop
was outfitted with a new cycle-lathe. The machinepark is now divided into two areas: conventional
machines for basic training and specialized
devices for CNC specialization and production.

THE STUDER SOCCER TEAM won the UNITED GRINDING
CHAMPIONSHIP 2022. All companies in the UNITED
GRINDING Group take part in the annual soccer tournament,
held this year on September 3 at STUDER at the facilities of
FC Rot-Schwarz Thun. A total of seven teams competed forthe title; STUDER ultimately claimed the title 7: 6 after apenalty shootout over runners-up WALTER Kuřim. BLOHM
JUNG took third place. Host STUDER also offered theparticipants a guided tour of the plant and a festive evening
event at the Zündkapselfabrik in Thun, where the medals
were awarded.

CHINA

LAUNCH OF ECOGRINDER SALESCZECH REPUBLICNEW MACHINING CENTERIN KUŘIM

ECOGRINDER, A CNC UNIVERSAL CYLINDRICAL GRINDING MACHINE developed by
STUDER for the Chinese market, is now available. Sales started in June witha virtual unveiling show. The ecoGrinder machine is designed for grinding
medium-sized workpieces in single and series production. It features
distances between centers of 650 (25.8") or 1000 millimeters (40") and acenter height of 175 millimeters (6.89"). It can machine workpieces with amaximum weight of 80 kilograms (176 lbs) or 120 kilograms (265 lbs). A
solid Granitan® S103 machine base provides the foundation for thecylindrical grinding machine, which is equipped with high quality
components, thus guaranteeing maximum precision,
performance and reliability over many years.

WALTER HAS INVESTED in a new machining centerat its Kuřim site. The machine with a μ-Precision
package will be used to produce a strategic
range of precision parts for WALTER machines,
such as grinding spindle slides or axles. The
DMC operates with an accuracy of up to 4 μm
(0.00016") and has a new type of rotary magazine
for 250 tools. The operation of the fully climateconditioned machine is integrated into thecompany organization. This investment increases
the site’s production capacity for mechanicalprocessing by around a third.

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UNITED GRINDING GROUPINNOVATIONWith its IMPACT 4530, the UNITED GRINDING Group has developed theworld’s first “Made in Switzerland” additive machine tool for industrial use—from the small town of St. Gallen. How was this success achieved?
TEXT: Michael Hopp

PHOTOGRAPHY: Thomas EugsterTHE
MIRACLEThe Roman Catholic Stift Church and Cathedralof St. Gallen, built in the monumental
style of late Baroque period, lies only a few
kilometers from the innovation hub where
IRPD developed the IMPACT 4530

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MÄGERLE

BLOHM

JUNG

STUDERSCHAUDTMIKROSAWALTER

EWAG

IRPD

FROM
ST. GALLEN
The IMPACT 4530 uses 3D printing to
produce high-quality metalcomponents in all possible shapes
and structures

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UNITED GRINDING GROUPINNOVATION

Components manufactured using 3D metal
printing from IRPD are of the highest quality andmeet even the strict demands of industry

THE CLEAN NEW TURNKEY IMPACT 4530 stands
in a room at the St. Gallen IRPD R&D center
that was built especially for it. Its reputation
already far proceeds it: the world's first industry-ready machine for additive manufacturing. There's no grinding of workpieces inthis case; “manufacturing” in this case is actually precisely the opposite process. “Unlike classical production technology, wherematerial is removed from a solid block bymachining,” explains Paul Kössl, Head ofBusiness Development and Marketing of
UNITED GRINDING Group, “metal powder
is used to build up a component additively,
bit by bit as a layer beam melts it layer bylayer (LPBF process).”The “face” of the IMPACT 4530 is an almost human-sized 54-inch touchscreen

display in a friendly and intuitive design. This
human-machine interface transmits the live
images of the micro-welding process from acamera installed in the installation space andcombines them with control elements and information on the process sequence. UNITED
GRINDING Digital Solutions™ transfers data
to the C.O.R.E. operating system. “It was a
priority for us to integrate the IMPACT 4530
into the highly automated system network in
a user-friendly way, enabling efficient networking with other machine tools,” says Kössl.

THE DANCE OF THE LASERThe IMPACT 4530 consists of two separate
decoupled machine units. The thermostabilized, vacuum-capable machine core built ona cast-iron machine stand, the construction“IN THE 3D PRINTING PROCESS, COMPONENTS ARE CREATED THATWOULD NOT BE POSSIBLE WITH CLASSIC MACHINING.”
Alex Frauchiger, Head of Process and Material Development

The different metal
powders are stored
separately in the IRPD
Job Shop in 37-liter
special containers
with rollers. The labels
here stand for thealloys: stainless steel(l.) and aluminumsilicon (r.)

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MÄGERLE

BLOHM

JUNG

STUDERSCHAUDTMIKROSAWALTER

EWAG

IRPD

THE PREVIOUS
GENERATIONSThe IMPACT 4530 is a thirdgeneration AM machine tool
based on 20 years of experience.
The two previous models arestill in use today
LAB 00The 54-inch 4K screen allows aview into the system via to a camera
installed in the interior

space, and the supply unit designed as a
welding construction are successfully implemented as a separate operating and loading
area. Together with the integrated automatic changeover system for the gas-tight metal powder containers and the components,
this ensures the machine operable nevercomes into contact with the metal powder.
While the IMPACT 4530 goes about its
work, the screen shows the lasers dancing
like four yellow flames, building circles,
lines, corners, and edges atop a layer of themetal powder. This process is called selective laser melting of metal powders in the
LPBF process (Laser Power Bed Fusion),
which it handles with two or four 1000-wattindustrial fiber lasers.

IDEAS IMMEDIATELY BECOME REALITY
The metal components are ultimately welded together layer by layer on the plate. The
metal powders are offered in different grades
and in steel, aluminum, titanium and nickel-based alloys as well as special metals—
the right selection and mixing is crucial forthe quality of the products. One of the greatest advantages of 3D printing is that new,creative ideas can be implemented quickly
and at low cost, says Michael Schneider,head of additive services & customer care
at IRPD. “This inherently leads to bettercomponents and thus to better products.”
Alongside Pascal Brunner, Kai Gutknecht,
and Alex Frauchiger, Schneider is one of theexperts who has been closely involved in the

The success story of the IMPACT 4530
began with the LAB 00 (pictured above). Thismachine has by no means been put out topasture, but rather is still at work providing important insights in material and process parameter development. The hard-won knowledge it
provides is expected to deliver a future where
each IMPACT machine will be ready to engage
in up to four different production strategies
involving a wide range of materials, all tailoredto the customer's requirements. The focus ison high productivity, high material density, top
surface quality, and low component costs.

LAB 01
The LAB 01 (pictured below) was the start of
the next generation, and has been used by
IRPD in recent years to produce components
for internal or external customers using theadditive manufacturing process. Numerous
cooling nozzles for MÄGERLE, BLOHM, JUNG
were also produced and refined together withthe development departments of IRPD's
corporate sibilings, always taking into accountthe required functions and requirements.

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UNITED GRINDING GROUPINNOVATION

Pascal Brunner knows every detail of IMPACT 4530 andworks daily on potential optimization

The process chamber with the construction
space, which can process the four
lasers completely in a superproductive andautonomous manner

development of the IMPACT 4530 since2016. Schneider explains creating workpieces seemingly out of nothing requires only
the CAD 3D data of the desired component,
which the printer uses to calculate the various layers. For example, the movement planfor the deflection of the laser is created by amirror system, which melts the individual
layers at specific points, thus fabricating thecomponent.
“The 3D printing process allows for components to be created that would not be possible at all using classic machining,” says Alex Frauchiger, who is responsible for process and material development. This isperhaps the most important principle in theuse of additive manufacturing. It is not aquestion of replicating the classic process,but rather rethinking the components themselves and thus realizing the added value ofadditive manufacturing. “It always starts
with the analysis of where additive manufacturing actually adds value,” he explains.
This might involve faster production, newfunctions, or a combination of features.

3D PRINTING HEDGES AGAINSTSUPPLY CHAIN ISSUES
Speed is an important factor, agrees Pascal
Brunner, who is responsible for product development and IMPACT mechanics. “Notools need to be changed, no new blanks
need to be clamped, and the machinedoesn't needs to be adjusted for each job,”he says. All that's needed is the CAD 3D
software file containing the relevant pro-“IN THE END, CUSTOMERSBENEFIT, WHICH WE CONSIDEROUR GREATEST SUCCESS.”Paul Kössl,Head of Business Development and Marketing
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cess data. By eliminating setup time,
IMPACT can be warmed up in minutes andis highly flexible. Thanks to these advantages, it is suitable for the fast production of alarge number of complex components,from single-unit batches to series production—for spare parts, standard production,and prototyping.
“The tailor-made component topology
helps optimize a variety of processes andactivities related to the different aspects ofmechanical engineering,” explains material
expert Frauchiger, “because the functionality of tools and components often depends
on their surface.” Additive manufacturing
can be used to manipulate properties in atargeted way, including corrosion and wear
protection or sliding and lubricant behavior,adapting them seamlessly to customer requirements. The potential audience is hugeand diverse: the classic job shop, automotive suppliers, or the aerospace industry.

INNOVATIVE ATMOSPHERE
How could so much innovation have possibly come from this team in the small townof St. Gallen? First of all, IRPD is no ordinary
mechanical engineering company. Startingwith its modular building on Lerchenfeldstraße featuring plenty of glass and style, theMÄGERLE

BLOHM

JUNG

STUDERSCHAUDTMIKROSAWALTER

EWAG

IRPD

These are cooling nozzles from theAM process that IRPD is developing
and optimizing together with
BLOHM JUNG

innovation and media hub is known as a“starting block” across the region. Machines
stand here like polished exhibits, with ayoung engineer appearing now and again, aplexiglass visor over his face, to check on one
thing or another. Its a contagiously good atmosphere, where everyone can feel like they
are part of something big. The company’s origins in the nineties lie in an ambitious university project entitled “Institute for Rapid
Product Development,” established at theIntercantonal Engineering School of St. Gallen(ISG), the university of applied sciences, andthe ETH Zurich.
“Being able to experience the interplay
between research and development up closeand personal and tied to the provision of services, that's unique,” says Frauchiger. The
team proudly shows the two predecessor
models of the IMPACT 4530, a pair of machines still in use on a daily basis for the refinement of AM processes or for the production of components. The new 4530 is therefore the third generation of the machine,
albeit one now capable of meeting the highdemands of industry.

THE SPIRIT OF ST. GALLEN“THE IMPACT 4530
COMES WITH THE
REVOLUTIONARY C.O.R.E.
HARDWARE AND SOFTWARE ARCHITECTURE,
MAKING IT COMPATIBLE
WITH ALL OTHER BRANDS
IN THE GROUP.”
Kai Gutknecht,
Head of Software Development

This university-style start-up spirit is one factor why one of the most innovative machine
tools in the world was developed here in
St. Gallen, just a few kilometers from themagnificent Baroque cathedral. The otherreason is the integration into a leading international group of machine tool construction
companies. The UNITED GRINDING Grouphas been the sole shareholder of IRPD since2019, but enjoyed a long-standing cooperation long prior to that. “We can take advantage of synergies, and if we need support,
we can find it, both in terms of expertise andcapacity,” reports Michael Schneider. The
IMPACT 4530 is being developed in St. Gallen,
but is being built by its sister company
STUDER in Thun, some 200 kilometers away.
On the other hand, the sibling firms also benefit from additive manufacturing at IRPD. For
example, the nozzles of the new SmartJet®
cooling system are produced using the 3D
printing process.
Customers also benefit from synergies
in terms of user-friendliness, networking, intelligent data processing, and automation:“The IMPACT 4530 comes with the C.O.R.E.
hardware and software architecture, so it iscompatible with all other brands in theGroup,” explains Kai Gutknecht, who is responsible for software development. “Thestrong cooperation here in the team and with
UNITED GRINDING,” he adds, “is the main
reason why the IMPACT 4530 exists today.”
There are nodding heads, smiling faces, anda good mood. “In the end, the customers
benefit, which is the greatest success forus,” says Kössl and heads out from the“starting block” on Lerchenstraße, to themountain landscape of St. Gallen, a place
where a minor miracle has happened with
the IMPACT 4530—one of teamwork, knowhow and the conviction that extraordinary
things can be achieved with the right will.

The technical specifications of the
IMPACT 4530 and their benefits at a glancecan be found here in the magazine in the“Tools & Technology” section on page 28.
Lessons learned: Pascal Brunner, Alex Frauchiger, Kai Gutknecht, andMichael Schneider (v. l.) share their experiences daily

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UNITED GRINDING GROUPINDEPTHLEARNING THE STATE
OF THE ART
The modern transfer of knowledge and the development ofyoung staff are becoming increasingly important at thecompanies of the UNITED GRINDING GroupTEXT: Markus Huth

IN AN INDUSTRIAL HALL, A GIANT OF A MAN
WITH TATTOOED ARMS walks past machine tools from the UNITED GRINDING
Group and speaks into the camera: "TheBLOHM, the STUDER, the WALTER: We’ve
got a series for each individual machine,
and we’ll show you the journey of how
they arrive, how we set up and install themand then configure them." The man is Titan
Gilroy, and many on the CNC scene know
the story of the US ex-boxer from being acriminal to a successful entrepreneur andstar of the popular video-forming platform“TITANS of CNC.” Gilroy is now working with
the UNITED GRINDING Group to share hisknow-how and inspire young people to be-

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come professional grinding techs. His series, the “GRINDING Academy,” went live inJuly 2022. The free tutorials invite grinding
enthusiasts to acquire valuable knowledge.
"The precision and quality that is possible
with CNC grinding should be better known.
The academy will highlight all these possibilities and show viewers how they can use
them," says Paul Kössl, Global Head of Marketing & Business Development at UNITED
GRINDING Group.
Knowledge transfer — the topic is playing an increasingly important role. Whether
online or in person, as an offer to the generalpublic, customers, in-house junior staff, or
technical specialists. If you want to survive
in times of skilled worker shortages and digitalization, you have to build up a reputation
for imparting knowledge and training using
modern methods and up-to-date technology.
Angela Fahrenkrog, who has taken on
the newly created position of training officer
at BLOHM JUNG, has observed the samething. “The tables have turned, and nowadays, we’re trying to convince the few qualified candidates of why they should workwith us, and not the other way around,”she says. The company with 220 employees at locations in Hamburg and GöppingenMÄGERLE

BLOHM

currently has three trainees. Fahrenkrog’s
three-person team handles support andacts as an interface to the individual departments. Her tasks also include presenting
the company to potential young talent: “This
year, we will be represented for the first timewith a stand at the dream career high school
fair in Hamburg.”

TRANSFER OF KNOWLEDGE FORYOUNG PROFESSIONALS AND
SPECIALISTS

Photos: David Schweizer (2)Recruiting new talent nowadays also means
clearing up old stereotypes: This is why
WALTER regularly takes part in “Girls’ Day”,
the world’s largest career orientation project for female students. The aim is to bringgreater interest and involvement by girls in
professions and fields of study in which theproportion of women is below 40 percent.
“We are visited by as many as five female
high school students in the assembly hall

JUNG

STUDERSCHAUDTMIKROSA

every year, looking to find out more about
the practical side of working as a mechatronics technician,” says Celine Ruckaberle, whooversees the project.
STUDER also gives young people an onsite tour of the company, letting them know
about the attractive career opportunities. At
the ‘Future Day’ every year, young people
from the region can visit the Thun locationand learn more about the work of automation technicians, automation system assemblers, the sales force, designers, logistics
specialists, and polymechanics. In addition,
there are multi-day “test apprenticeships,”
which draw up to 200 high school students
each, notes Michèle Zeller, head of marketing communication at STUDER. In addition
to attracting young talent, training and continual professional development of in-house
technical specialists is another important aspect of modern knowledge transfer. This isbecause they are increasingly spread around

WALTER

EWAG

IRPD

the world, in order to be as close as possible to the customer. The “WE Academy” at
WALTER and EWAG, for example, was set
up for the internal transfer of knowledge insales, service, and applied engineering. “Allemployees worldwide are trained online andin person as required to ensure they arebringing our customers up-to-date knowledge,” says Christoph Ehrler, head of marketing at WALTER and EWAG.
STUDER trains its service specialists andcustomers at the “STUDER Academy,” using
digital multimedia equipment with cameras
to complement face-to-face teaching and online instruction (live on machines and on-demand videos and documents). This meansthat the most complex knowledge and knowhow can be acquired from anywhere in theworld. Because at UNITED GRINDING, it all
ultimately comes down to quality and trust,whether it’s the learning is conducted digitally and remote or face-to-face.

1. STUDER uses its own multimedia equipment for the online training of technical service personnel. 2. Two female high school students at the“Girls’ Day” at WALTER 3. High school students can complete a multi-day “trial apprenticeship” at STUDER 4. BLOHM-JUNG mechatronic
trainees 5. Well-known CNC trainer Titan Gilroy collaborates with the UNITED GRINDING Group on his online knowledge platform “Grinding
Academy.” 6. The “WE Academy” provides training for applied engineering experts from all over the world 7. One of the “Girls’ Day” activities at
WALTER involves pouring liquid metal into molds 8. A high school student at “Future Day” at STUDER

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UNITED GRINDING GROUPINSIDESIMPLYGOODPEOPLE –EVERY- “KNOWLEDGE“SOFT SKILLSMUST BE APPLIED IN MATTER TOO.“
WHERE PRACTICE.“
The companies of the
UNITED GRINDING Group
operate in many countries on
numerous continents. Our
employees speak different
languages and come fromdifferent cultures – which
demands talented humanresource managers. “Motion”
introduces five of them

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HELENA WANGULRIKE ETTELPOSITION: Director Human Resources,
UNITED GRINDING China, Shanghai

POSITION: HR Director BLOHM JUNG,
Hamburg, Germany

CONTACT: Helena.Wang@grinding.cn

CONTACT: Ulrike.Ettel@blohmjung.com“I SEE THE NURTURING OF SKILLS and talents in
our employees, especially with regard to theneeds of the company, as the main task for
Human Resources,” says Helena Wang. A
graduate in intercultural communication,
she heads the HR department and has beenworking for the company for six years. She
always follows one guiding principle: Knowledge alone is not enough, it must also be
possible to put it into practice. “That is an ancient Chinese philosophy,” she says. Wangis currently working on the implementationof an E-HR system.

“THE FLAT HIERARCHIES of a medium-sizedcompany, combined with the international environment of the UNITED GRINDING
Group, give our employees real scppe fordevelopment and global opportunities,” says
Ulrike Ettel. The business administration
graduate started working for the company
in 2005 and is now responsible for the entire
operative and strategic spectrum of humanresources at two locations. Her sharpest
focus is on recruiting new talent, advising
managers, and ensuring attractive working conditions. “We put a lot of emphasis
on retaining our employees,” says Ettel. In
addition to professional qualifications, theyshould also have soft skills such as a senseof responsibility and teamwork.

BLOHMJUNG

STUDERSCHAUDTMIKROSAWALTER

EWAG

IRPD

Photo: David SchweizerMÄGERLE“GOOD TEAM SPIRIT
MATTERS.”HANSUELI SCHÜRCH

“WE ARE AN
ATTRACTIVE AND
STABLE EMPLOYER.”

KATEŘINA HÁLOVÁPOSITION: HR Manager STUDER,
Thun, Switzerland

POSITION: HR Manager WALTER,Kuřim, Czech Republic

CONTACT: Hansueli.Schuerch@studer.com

CONTACT: Katerina.Halova@walter-machines.de“I LOVE HELPINGPEOPLE.”AMY LUTHER
POSITION: Director of Corporate Human
Resources UNITED GRINDING
North America, Miamisburg, USA
CONTACT: Amy.Luther@grinding.com“WE ARE AN EMPLOYER with a long tradition, astrong reputation, and good roots in the region,” explains Hansueli Schürch. The university-trained HR manager and master mechanic has been working for the company
for 33 years. His tasks include the recruitment, support, and professional development of employees. In addition to professional cooperation, a good team spirit withjoint leisure activities is important to him.
Schürch also considers the offer of flexible
working time models and home office options as essential for a modern employer.
“Due to the shortage of skilled workers,
companies will increasingly have to market
themselves to potential candidates,” hesays. Schürch likes the variety inherent to
his responsibilities and is currently working
on the digitization of HR processes, among
other projects.

“WE ARE KNOWN FOR HIGH-PRECISION WORK in amodern technological environment and havebeen a stable employer on the market for 25
years,” says Kateřina Hálová. These factors
make her company a very attractive employer for the employees. A lawyer by trade, she
specializes in human resources and labor law
and has been working for the company formore than five years. As HR manager, shefeels it is important that employees have thebenefit of continuing professional development, language courses in German andEnglish, as well as fair working conditions.
“The ability to identify relationships, engage
in open communication, and a sense of helpfulness are fundamental characteristics that
employees should have,” she says.

“WE WANT TO EQUIP EVERY one of our employees with the necessary toolbox to be able towork at the highest level,” explains Amy Luther. She studied economics, communication
and analytics and has worked in HR for over
25 years, the most recent three with ourcompany. Online and in-person training
courses are available for employees, as is anoffer for tuition fees reimbursement. Beyond
the technical skills of the team, Luther seessoft skills such as a good customer service
attitudes as important. She takes particular joy in the side of her work dedicated tohelping people achieve a happy and fulfilling
professional life, while at the same time satisfying customers with first-class products.

Motion 02.2022

17

UNITED GRINDING GROUP

INTERVIEW“WE’RE WELL UNDERWAY”

18

Motion 02.2022

MÄGERLE

BLOHM

JUNG

STUDERSCHAUDTMIKROSAWALTEREWAG

IRPD

The UNITED GRINDING Group’s IMPACT 4530 is the world’s first ‘Made in
Switzerland’, industrial format additive machine tool. In an interview withProfessor Markus Bambach from ETH Zurich, CEO Stephan Nell explains thepotential of the new technology
TEXT: Michael Hopp

PHOTOGRAPHY: Thomas Eugster

The interview participants at theTechnopark Zurich (from l.): Professor
Markus Bambach, CEO Stephan Nelland Editor-in-Chief Michael Hopp

Motion 02.2022

19

UNITED GRINDING GROUP

INTERVIEW

Michael Hopp is
editor-in-chief of Motion

Mr. Nell, does the UNITED GRINDING
Group with the IMPACT 4530 strive to become the technology leader in machine
tools for additive manufacturing?
Stephan Nell:We certainly want to be at theforefront. There are many established manufacturers with years of experience with additive manufacturing and a solid track record.
But we wanted to bring our own DNA to the
topic, and this includes high reliability andavailability. Our focus is always on making
our customers successful. By offering thebest technology available.
What's the strategic value of this area?
Stephan Nell: Additive manufacturing can be
one manufacturing stage prior to grinding,and it goes to certain consumer industries
that represent potential customers for 3D
printing. And it is, of course, a new manufac-“YES, I CERTAINLY THINK WE
ARE DEALING WITH A
TECHNOLOGICAL LEAP HERE.
WHAT MATTERS RIGHTNOW ARE THE SOFTWARESOLUTIONS.”
Markus Bambach

20

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MÄGERLE

BLOHM

JUNG

STUDERSCHAUDTMIKROSAWALTER

EWAG

IRPD“I BELIEVE IN THE
THING THAT
GENERALLY DRIVESTHE MECHANICALENGINEERINGINDUSTRY: CONTINUOUS INNOVATION.”
Stephan Nellturing field that requires a lot of innovation.
After all, grinding has been around forever,
it's fair to say. The only way forward is evolutionary. Of course, new innovations areconstantly being added and the machines
are getting better and better. But there are
no new giant steps. By contrast, 3D printing
is a fundamentally new technology. And thatcaught our attention.
Mr. Bambach, can we already say withcertainty today that additive manufacturing represents a real technological leap?
Markus Bambach: Yes, I certainly think weare dealing with a technological leap here.
If you think back to the first industrial revolution, where the loom was invented andlater made programmable with a punchedcard, you can find many examples over time
when hardware and software innovation
went hand in hand to create a technologicalleap. Additive manufacturing needs be nodifferent – we must have a good machine on
the hardware side, while also mastering theentire chain on the software side.
Mr. Nell, how exactly did you enter into thisnew field of technology, because it's notthat kind of thing you can simply decide
to do overnight.
Stephan Nell:Yes, it was a bit of a journey.
We started by imagining ourselves in the roleof the customer to such a machine manu-

facturer. This is what we did with Inspire —who have experience with 3D printing since
1996, and we subsequently gained accessto this network directly with the purchaseof IRPD. And then we let the development
team and the Inspire people with previous
3D experience come together with the instructions: Do your thing. The result is the
IMPACT 4530 – 9.2 tons of Swiss mechanical engineering.
Mr. Bambach, is the UNITED GRINDING
Group simply following the textbook here?
Markus Bambach: No doubt, there are someunique selling points for additive manufacturing. For example, cost per component canbe made more independent of the complexity of the components and the number ofunits. That’s not the case with other procedures. In addition, production can be handed
locally, in a decentralized fashion. Nevertheless, one must always think about the cost
structure in production chains. And if thecost question is dominant, then you can't
make the case commercially for additive
manufacturing as we know it today. Because
it often takes a relatively long time and requires a lot of experience before a component can be printed at all. For more complex
components and more difficult applications,
you’ll need to hire a team of engineers andlet them work for several weeks before you
actually have a component that meets the

TAKING PART IN THE
DISCUSSIONMARKUS BAMBACH
Markus Bambach is Professor of New Manufacturing Technologies at ETH Zurich and headof the Advanced Manufacturing Laboratory. His
research focus is on new manufacturing technologies, with a particular interest in additive
manufacturing.

STEPHAN NELL
Stephan Nell has been Chief Executive Officerof the UNITED GRINDING Group worldwide
since 2012. He joined STUDER in 2003 as SalesManager for Europe and served there as Chairman of the Board from 2007 to 2011.

MICHAEL HOPP
Michael Hopp is editor-in-chief of Motion andalso owner and managingdirector of Hopp andFrenz Content House in Hamburg.

Motion 02.2022

21

UNITED GRINDING GROUP

INTERVIEW

requirements. But UNITED GRINDING now
has a very solid machine on the market — ona market in which it is already established.
These are very good prerequisites.
Mr. Nell, Mr. Bambach still seems to be
waiting for the technology to keep advancing.
Stephan Nell: We never believed that additive manufacturing should replace grinding.
On the one hand, the process does not offer
the same surface quality. Nor can it match its
precision. But it does provide us with a newgenerative process upstream of the grinding
machines that can enhance their abilities. It is
one of many technologies that complements
our existing portfolio well. If you look at aMÄGERLE machine tool today, it can not
only grind, but also mill and drill. It is a machining center. At WALTER EWAG, we developed laser technology. Many people don't
even know that we produce more measuringmachines than some of the leading special-ists in that technology. Additive machine
tools also fit into this concept.

“TODAY WE KNOW SO
MUCH ABOUTTECHNOLOGY THATWE ARE CAPABLE OFEYEBALLING IT.”
Stephan Nell

In conversation with the young engineers at
IRPD in St. Gallen, the idea was that additive
manufacturing would give us better products overall. Where do you see the boundaries of this utopia?
Stephan Nell: Here’s what the engineers
got right: 3D production can open up completely new possibilities for designers. Firstly,
they have to learn to design a part in sucha way that they can take the advantages of
3D printing. There is no point in moving an
existing part that is being made today on
a milling machine or lathe one-to-one to a
3D printer.
Markus Bambach: If you were to sell a 3D
machine to a service provider who earns
money in the machining sector, without adesigner — it’s unlikely you’d end up with
better parts. After all, they're still thinking interms of a design to be manufactured by machining. The successful examples I’m awareof come mainly come from the hydraulics
sector. Or cooling, where integral parts canbe printed instead of producing many individual parts. These examples each showa technological leap in which the potential
is systematically increased. For example,
in the aerospace industry, where extreme
lightweight construction is possible. Then
we can look at medical technology, whereindividualized components are important.
But it’s a little too much for me to say right
now that the technology inherently means
better products for society. The largest 3Dseries production I know is a couple of tensof thousands of designer spectacles per year.
It’s just not possible to produce two million
parts – the technology has its limits.
Stephan Nell: There are limits, of course. But
at the same time, we can observe progressunderway. To this point, most 3D printers
have been used in the metallurgy departments at universities and in testing departments of companies. But now customers
want to use the machines for industrial production and are not interested in optimizing
processes. They want it to work. And that’s
what the IMPACT 4530 does.
What exactly are customers’ requirements
for an industrial-grade 3D printing machine
tool?
Stephan Nell:It must run stably, work quickly, and not make any mistakes. This is why
the IMPACT has up to four lasers with 1,000
watts each. They do however naturally leave
traces of smoke residue, which must be
dealt with. Then there are seemingly simple

22

Motion 02.2022

MÄGERLE

BLOHM

JUNG

STUDERSCHAUDTMIKROSAWALTER

EWAG

IRPD“THE POTENTIAL OF THIS TECHNOLOGYMUST BE INCREASED SYSTEMATICALLY.
TO DATE, THIS HAS ONLY HAPPENED ON
A CASE-BY-CASE BASIS.”
Markus Bambach

things: We monitor the lip that coats the material, and replace it automatically if a defectis detected to prevent it from continuing tooperate improperly. And then it is also important, at an industrial process level, thatthe customer does not have to constantly
monitor the machine with personnel, whichcosts money. It must therefore have a highlevel of autonomy and largely be able tomonitor itself. Generally speaking, parts andmaterial change, and the machine needs tobe able to deal with that. I cannot lose one
or two shifts just to change materials. We
take just 120 minutes to change materials,
and it takes 15 minutes from job to job. In
addition, we have many customers who mill,turn, grind, who have many production technologies in-house with a correspondingly
high headcount. They’ll need to integrate
3D printing accordingly. So I need to design
the machine in such a way that there is nocontamination of the environment. Because
people must not come into direct contact
with the metal powder.

That sounds like the right way to go.
Perhaps this utopia is attainable, Mr.
Bambach?
Markus Bambach:Perhaps, presuming additive manufacturing continues to evolve as atechnology. But I don't yet view it as beinga substitute for established mass production-capable technologies, so to speak. Ongoing development of the software solutions
is also important.
Stephan Nell:I think it’s great to orient oneself towards Utopian ideas. And the IRPD
team in St. Gallen is hard at work optimizing
the software solutions. In the end, it is anefficiency question for most customers. Ecological aspects also play a major role here.
Additive manufacturing has a lot of potential
in this area. There’s less need for transportation, and supply chains can be shortened.
I am convinced that additive manufacturing will find its way into the machine toolindustry. But it will not displace or replace
everything else.

Motion 02.2022

23

UNITED GRINDING GROUP

A DAY WITH …

PASSION FORTECHNOLOGY
Kirsten Brinck heads up the technology
department at BLOHM JUNG and,
together with her team in the company,
drives innovation
TEXT: Markus Huth

PHOTOS: Dennis Williamson“I REALLY ENJOY ANALYZING AND SOLVING technical challenges,” says
Kirsten Brinck, head of technology at BLOHM JUNG. Her teamof 31 engineers, two working students, and external service
providers are responsible for mechanics, electrics, software,and driving innovation in surface and profile machines at theHamburg location. A university-trained mechanical engineer bytrade, Brinck has worked for the company since 2019 and previously held various specialist and management positions in themechanical engineering industry. “I also really enjoy coordinating
and motivating my team,” she says, adding: “Because ultimately,
the customers benefit.”
CONTACT:
Kirsten.Brinck@blohmjung.com

9:00 A.M.
START OF THE DAY
The day starts for Brinck at the BLOHM site in
Hamburg with phone calls and virtual meetings with
her team, some of whom are working from home.
She then heads over to the assembly building to get
an overview of the tasks

24

Motion 02.2022

MÄGERLE

BLOHM

JUNG

STUDERSCHAUDTMIKROSAWALTER

EWAG

IRPD

10:15 A.M.
ASSEMBLY BUILDING
For a brand-new project, Brinck works
with employees from other areas such as
Sales, Purchasing, Customer Care, andAssembly to identify and harness potential
improvements to an existing machine.

NOONTEST BUILDINGIn addition to good grinding performance, theprojects are all focused on improving production costs
and energy efficiency in the machines. To this end,
Brinck’s team not only prepares theoretical calculations, but also validates them on the machines.

“TECHNICAL MANAGEMENT STAFF
SHOULD PROVIDE THEIR COLLEAGUESWITH QUICK AND OPTIMAL SUPPORTTOWARD A SOLUTION.”
Kirsten Brinck

2:00 P.M.
OFFICE FOR MECHANICAL DEVELOPMENT
Development Engineer Henning Federmann talks
with Brinck about his project to validate the recently
ordered PL/PR XT machines and the best way toimplement the customer requests

Motion 02.2022

25

UNITED GRINDING GROUP

A DAY WITH …

3:00 P.M.
FINAL INSPECTION
Together with software programmer Phil Clasen,
Brinck does a final inspection of the new
PLANOMAT XT with tool changer before it
starts its journey to the USA. “The tests were all
positive,” she says.

“WE APPLY EFFICIENT WORK PROCESSESAND THE PRINCIPLES OF GOOD TECHNICALDESIGN AND DEVELOPMENT TO HELP OUR
CUSTOMERS SUCCEED.”
Kirsten Brinck

5:00 P.M.
ON THE WAY TO THE OFFICE
Towards the end of the working day, a numberof technical evaluations and presentations stillneed to be prepared to serve as a basis forimportant decisions

26

Motion 02.2022

4:00 P.M.
OPTIMIZATIONThe continuous improvement of design andefficiency in mechanics, electrics, software, anddocumentation is very important to Brinck and herteam and are given regular focus every dayMÄGERLE

BLOHM

JUNG

STUDERSCHAUDTMIKROSAWALTEREWAGTOOLSTECHNOLOGY
NEWS FROM THE UNITED GRINDING GROUP

The new intelligent “Laser Contour
Check” measuring system fromWALTER enables accurate contact-freemeasurement

CONTENTS
28
29
29
30

IRPD
IMPACT 4530 is a new additive manufacturingmachine tool for industrial applications
BLOHM
The new automatic tool changer for the
PLANOMAT XT saves time and ensures efficiency
BLOHM JUNG
The special software on the PROFIMAT XT is the
key to its precise and durable thread rolling dies
STUDERThe S100 is the new CNC universal internal
cylindrical grinding machine with top STUDER
quality for the entry-level segment

31

32

33

WALTER
The HELICHECK NANO is the first automatablemeasuring machine capable of measuring microand nanotools non-destructively
WALTER
Rotationally symmetrical tools withcomplex geometries are no problem for the
HELITRONIC MINI PLUS
WALTER
The intelligent “Laser Contour Check”
measuring system is ideal for precise yet
contact-free measurements

IRPD

UNITED GRINDING GROUPTOOLS & TECHNOLOGYThe IMPACT 4530 from IRPD
comes with the C.O.R.E. hardware
and software architecture.

TRAILBLAZING
IRPD’s new IMPACT 4530 is the world’s first industrial-grade,‘Made in Switzerland’ additive manufacturing machine tool,and provides continuous process conditions

THE IMPACT 4530 USES THE LASER POWDER BED
FUSION (LPBF) PROCESS for workpiece production: With a choice of two or four industrial
1000-watt fiber lasers, it can selectively melt
metal powder, thus producing modular andscalable high-quality components for theclassic job shop, aerospace, automotive,

energy, medical, tool, and automation sectors. “The IMPACT 4530 can handle all common metals and is the world’s first 'Made in
Switzerland’ industrial-grade AM machine
tool, with stable reproduction conditions,accuracy, quality, and scalability,” says
Luigi Retta, Key Account Manager at IRPD.
The microwelding process takes place inthe thermostabilized machine core of
the IMPACT 4530. At the heart of this is thevacuum-capable process chamber, an ultra-rigid and robust cast component that ishermetically sealed together with the buildand powder storage containers. This innovative system design guarantees high productivity and safety. The separation between
the operating and loading area, as well as anintegrated automatic changeover system forthe gas-tight metal powder containers andthe components, ensure operation without
powder contamination. This design ensures
short auxiliary times (job-to-job in 15 minutes) and fast, flexible material changes. The
machine can be operated in a stand-alone
mode or in an automated system network.

FIT FOR THE FUTURE THANKS TO
C.O.R.E.
The IMPACT 4530 is delivered with C.O.R.E.,
the cross-brand hardware and software architecture of the UNITED GRINDING Group.
A 24-inch multi-touch control panel provides
simple, intuitive control of the system, which
also features smart software for efficient
networking with other machine tools.
CONTACT:
Luigi.retta@irpd.ch

THE BENEFITS AT A GLANCE	
Autonomous, scalable, and thermally stable	
Short auxiliary times
	
2 or 4 synchronized fiber lasers,1000 W each	
Automatic process monitoring with stateof-the-art sensor technology and 3D scannertechnology

	
C.O.R.E. hardware and software architectureincl. 24-inch full HD multi-touch display

	
54-inch display for a virtual view into thework area
The microwelding process takes place in
the IMPACT 4530's hermetically sealed
process chamber

28

Motion 02.2022

	Easy to maintain and clean	Up to 10 measuring sensors	Industry 5.0 standardMÄGERLE

BLOHM

JUNG

STUDERSCHAUDTMIKROSAWALTER

EWAG

IRPD

SURFACE AND PROFILE GRINDING
WITH TOOL CHANGERReduced set-up times and process-parallelloading of the tool magazine during surface
and profile grinding on the PLANOMAT XTA LACK OF SKILLED WORKERS, SMALLER LOT SIZES, and more demanding
products — the industry is tackling these challenges by automatingprocesses for more economic and efficient manufacturing. The newtool changer for the PLANOMAT XT represents BLOHM’s first automation option for profile and surface grinding, capable of reducing
auxiliary times and relieving the operator. The changer, which is fully
integrated into the control logic, replaces the grinding wheels on
the spindle based on the running program. It can also be fitted withnew wheels parallel to the process without disrupting the production
process itself.

COMPACT AND DURABLE“While we were developing the tool changer, we faced two challenges: the weight of the grinding wheel and the level of compactness for the changer magazine required by the market,” explains
Torsten Schulz, head of sales America at BLOHM JUNG. The newtool changer can be integrated into the machine environment ina highly space-efficient manner. The changing mechanism, which
grips the grinding wheels from the magazine and inserts them into
the spindle, can handle wheel weighing up to 40 kilograms without
problem — a significant relief for the users. Depending on the tool
width, the tool magazine can be equipped with five to eight grinding
wheels of diameters of up to 400 millimeters. These strengths on
the part of the tool changer are especially clear when machining
similar workpieces with different tools, during complete machining
in one clamping with different grinding wheels, and during highly
productive grinding with high wheel consumption.
CONTACT:
Torsten.Schulz@blohmjung.com

The new toolchanger on the
PLANOMAT XT is
automation-readyLong-lasting thread rolling dies
thanks to PROFIMAT XTFROM STANDARD TO SPECIAL
Thanks to the PROFIMAT XT profile
grinding machine and its high-powered
software, BLOHM JUNG offers everything
you need for grinding high-precision,
durable thread rolling dies
INCREASING AUTOMATION of manufacturing processes is driving
industry demand — especially in the automotive and aerospaceindustries — for high-quality screws with functions. Speciallyshaped threads ensure, for example, that screws center themselves when they are screwed in. At the same time, manufacturers are facing rising quality demands in terms of service life
and the quality of the thread rolling dies with which the screw
threads are produced.

HIGH MACHINE RIGIDITY AND POWERFUL SOFTWARE“Since ground thread rolling dies, in particular, are very
effective at satisfying the high demands for permanent
profile, shape, pitch, and surface accuracy, our customers are increasingly asking for technologies for grinding
thread rolling dies with special profiles,” explains Arne Hoffmann,head of technology and project engineering at BLOHM JUNG.
He refers to the company’s many years of expertise in this field:“Our PROFIMAT XT with its extremely rigid overall structure, highspindle power, and specially developed software is ideally suitedfor grinding high-precision thread rolling dies.” The PROFIMAT
XT is more than just an economic option for grinding common
metric thread profiles. When equipped with a CNC swiveling table
and counter bearing and a double Z-drive, it also enables efficient
grinding of thread rolling dies for highly complex screw shapes.
CONTACT:
Arne.Hoffmann@blohmjung.com

Motion 02.2022

29

UNITED GRINDING GROUPTOOLS & TECHNOLOGYThe S100, a CNC
universal machine forinternal cylindrical
grinding, delivers top
STUDER quality

TOP STUDER QUALITY AT THE ENTRY LEVELThe new S100, a CNC universal machine for internal cylindrical grinding, fills a gap in theportfolio at the entry level
THE NEW S100 CNC universal machine for internal cylindrical grinding offers proven STUDER
quality and excellent value for the highest precision in standard internal cylindrical grinding operations. As such, it is theideal universal internal cylindrical grinding
machine for the entry-level segment andexpands the broad portfolio of internal cylindrical grinding machines.
Like all STUDER cylindrical grinding
machines, the S100 also has a Granitan®
machine bed — an absolute must forconsistently good grinding results. In addition to a fixed wheelhead, it can be configured with a manual wheelhead with a
2.5 degree Hirth coupling or an automatic
wheelhead with a one degree Hirth coupling.
This allows the machine to be equipped withup to two internal grinding spindles or one
internal and one external grinding spindle.
A synchronous motor drives the grease-lubricated ID and OD belt-driven spindles.
The soft design of the machine enclosurepromises maximum functionality at minimized costs.
30

Motion 02.2022

AUTOMATION OPTIONWith this configuration, the S100 is ideallysuited for elementary grinding of a universal
range of parts with basic geometrically defined shapes and also contours that can begenerated with two interpolating axes. It also
has all the prerequisites for the external andinternal machining of flange parts, and thegrinding of special shapes such as threads
and non-circular forms. Typical workpieces
are collet chucks for tool making, bearing
rings and cylinders, as well as hydrauliccontrol valves in small series. Optionallyequipped ex works with a loader interface
and an automatic operating door, the S100
is ready for automation and thus for the production of larger series.
CONTACT:
Kaspar.Schaerer@studer.com

TECHNICAL DATA AT A GLANCE
Max. workpiece length: 550 mm
Max. swing diameter 425 mm
Max. (ID) grinding diameter: 180 mm
Max. Diameter (ID) grinding wheel 63 mm
Number of revolutions (ID) spindles:
20,000/40,000/60,000 rpm
Max. diameter OD Grinding Wheel
400 x 40 x 127 mm F1N(16 x 1.5 x 5" Form1N)
Workhead: ISO50/110 chuck workhead or
MK4/70 chuck workhead
Machine dimensions W x D x H:
approx. 3090 x 2090 x 1990 mm(121.6 x 82.3 x 78.3")
Machine weight: approx. 4,500 kg(9,920 lbs)

MÄGERLE

BLOHM

JUNG

STUDERSCHAUDTMIKROSAWALTER

EWAG

IRPD

THE FIRST OF ITS KIND
The HELICHECK NANO is
WALTER’s first automatedmeasuring machine for userindependent measurement of
microtools in the nano range

Photo: Hermann Kolbeck

THE TREND TOWARDS MINIATURIZATION in electronics, micromechanics and medical technology is driving demand for micro- andnanotools. Given that these tiny tools havediameters of less than one millimeter (0.04"),
comprehensive measurement is not possible. For the current crop of measurement
methods — including attempts to measuretools using microscopy — humans tend tobe the most common error factor. In addition, some measurements require the destruction of the tool, for example when measuring the rake angle of tools with end facegeometry. "Manufacturers must then hopethat the other tools are truly identical to themeasured ones. There is no proof," explains
Bernd Schwennig, who is responsible forproject management of measuring technology at WALTER.
HELICHECK NANO takes a different approach. This solution from WALTER offers
manufacturers of micro- and nanotools
non-destructive and user-independent measurement of their products. The new measuring machine reliably measures tools starting at diameters of 0.1 millimeter (0.004") intransmitted or reflected light. This is madepossible by a new variable optics systemwith up to 800x magnification, based on microscopic reflected light measurement technology. In combination with high-resolution
cameras, this microscopic optics systemforms the basis for measurements in the nano range. The variable magnification also enables measurements on standard tools up
to 16 millimeters (0.63") in diameter.

MEASURING LARGE SERIESOVERNIGHT
At the mechanical level, the HELICHECKNANO works similarly to its bigger siblings,
the fully automatic HELICHECK PRO andHELICHECK PLUS measuring machines.

Like them, it has a solid granite base, whichis crucial for the highest certified measurement accuracy and reliable measurement results. The fixed cameras are securely protected from dust and from external light inthe machine's enclosed measuring space.
The HELICHECK NANO also offers the option of automation. "Pallets with up to 7,500
tools can be measured automatically overnight without any operator involvement. Thisis an absolute innovation in the measurement of micro- and nanotools," says Bernd
Schwennig. Tools that do not meet the specifications are sorted out as rejects.
Although the measurement options of
HELICHECK NANO are already impressive,
they will be expanded in the future to include additional functionalities such as cutting edge rounding, 3D digitalization andmeasurement of surface conditions.

The microscopic optics of the
HELICHECK NANO allow measurements inthe nano range

THE ADVANTAGES OF HELICHECK NANO
AT A GLANCE:
Tool diameter 0.1 to 16 mm(0.004 to 0.63")
Non-destructive microscopic reflected

CONTACT:
Bernd.Schwennig@walter-machines.delight measurement
Works independent of operator
Can be automatedHighest measurement accuracy andrepeatability

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31

UNITED GRINDING GROUPTOOLS & TECHNOLOGYThe HELITRONICMINI PLUS is flexible
and individuallyconfigurable

MAXIMUM
FLEXIBILITY
The individually configurable HELITRONIC MINI PLUS tool grinding machine
grinds rotationally symmetrical tools with complex geometries and diameters from
one to 16 millimeters in one clamping

WHETHER FOR PRODUCTION OR REGRINDING, asa cost-effective basic machine or as a fully
automated tool grinding machine: The new
HELITRONIC MINI PLUS can do it all. “Thebasic version of the HELITRONIC MINI
PLUS can be individually configured withvarious efficiency options and loading systems — right up to the fully equipped highend tool grinding machine for all current
and future applications in the small and medium diameter range,” explains Siegfried
Hegele, product manager for applications
at WALTER.
The basis for the exceptional flexibility of
the HELITRONIC MINI PLUS is the unique
WALTER portal design. Economical production of standard and complex geometries is
ensured by the high-performance HSK
belt-driven spindle with two spindle ends for
up to six grinding wheels (standard equipment). The revolutionary C.O.R.E. hardware
and software architecture also delivers intuitive operation, setup, operation, networking, and maintenance of the machine.
32

Motion 02.2022

MULTIPLE OPTIONS FOR INCREASEDEFFICIENCYWALTER offers a wide range of options for
the HELITRONIC MINI PLUS for application-specific configuration. This includes, forexample, an automatic grinding wheelchanger for up to six grinding wheel adapters (maximum diameter 152.4 millimeters[6 “]), as well as a coolant distributor that ensures safe wheel set changes and maximum
flexibility. The “torque increase” option is also available for machines with a wheelchanger. It can increase the torque and removal rate by up to 60 percent, guaranteeing maximum productivity.
To automate the HELITRONIC MINI
PLUS, users can choose between a top loader and a robot loader with three different
equipment packages that promise evengreater flexibility. A top loader integrated into the working space offers a space-saving
and cost-effective automation solution. Depending on the tool diameter, it holds up to
500 tools. The robot can load up to 7,500

tools depending on the tool diameter or typeof tool. The maximum tool weight is five kilograms (11 lbs), the maximum diameter
125 millimeters (4.92").
CONTACT:
Siegfried.Hegele@walter-machines.de

TECHNICAL DETAILS
Diameter for production: 1 to 16 mm(0.004 to 0.63")
Diameter for regrinding: 3 to 100 mm(0.19 to 3.94")
Machining length 255 mm (10.04")
Tool weight: up to 30 kg (66 lbs)

BENEFITS AT A GLANCE
Individually configurable
Compact
Dynamic
Can be automatedEfficientMÄGERLE

BLOHM

JUNG

STUDERSCHAUDTMIKROSAWALTER

EWAG

IRPD

THE ADVANTAGES OF THE “LASER CONTOURCHECK” AT A GLANCE
Highly accurate measurement within
seconds
Automatic in-process correction of tool
diameter and profile
Using the “laser
contour check,”high-accuracy
measurements canbe carried out fully
contact-free

Suitable for automated series production
Fewer rejects

INNOVATIVE LASER MEASUREMENT
The new “laser contour check” intelligent measuring system enables
contact-free measurement in the machine
INTEGRATED TACTILE MEASUREMENT is standard equipment on WALTER grinding and eroding machines. It is now supplemented by the new “laser contour check” option. The innovative
measuring system for high-precision, contact-free measurementof a wide range of parameters on cylindrical tools with diametersfrom one to 52 millimeters (0.04" to 2.05") can also be integrated
into grinding and eroding machines. The measuring unit moves into
position when required. An innovative blue laser registers the tool
profiles and contours along its length and diameter, whether partial
or complete. Unlike tactile probes, the laser cannot wear out, which
eliminates the risk of measurement errors or potential damage to
cutting edges.

Measurement takes place directly via analog laser beam along theentire tool contour, not just selectively as is the case for tactile ordigital measuring methods. The system is also fast and accurate.
For example, a diameter measurement, including cleaning, takes
no more than 16 seconds (depending on the tool type) — with anabsolute accuracy of +/- 1.5 μm (60 mil). Deviations can be scannedand compensated for directly in the process. Operators can easily
program or adjust optimized program sequences for cleaning thetool with compressed air and compensating for deviations.
CONTACT:
Siegfried.Hegele@walter-machines.de

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33

UNITED GRINDING GROUP

INTERNATIONAL+150,000

MACHINES AND INSTALLATIONS
have been delivered to date worldwide by thecompanies of the UNITED GRINDING Group

13

>100

for the UNITED GRINDING Groupin Europein Germany and Switzerland

LOCATIONSYEARS OF GRINDING TRADITIONIRELAND

AT THE WESTERNEXTREME
9:00 A.M.

AROUND
THE WORLDIN ONE DAY
Around 2,500 people
worldwide work on behalf of
the UNITED GRINDING Groupat making our customers
successful
TEXT: Markus Huth

IRELANDGERMANYIN THE CITY OF LIMERICK, our partnercompany Acorn Processes is the westernmost representative of the UNITED
GRINDING Group in Europe. Under theleadership of Pat Murphy, who worked
for STUDER back in the nineties,
customers of BLOHM, JUNG, and
STUDER are provided with expert advice
and world-class technical service.

CZECH REPUBLICSWITZERLAND

WE ARE WHERE YOU ARE, the UNITED GRINDING
Group’s motto, is a promise to our customers
around the globe that they can count on
world-class service. The Group’s high-precision machines for surface and profile grinding(BLOHM, JUNG, MÄGERLE), cylindrical grinding (STUDER, SCHAUDT, MIKROSA), tool
grinding (WALTER, EWAG), and additive manufacturing (IRPD) are in high demand worldwide and can be found everywhere from large
industrial companies to mid-sized and small
workshops. There are 13 UNITED GRINDING
sales, service, R&D, and production sites in
Europe alone, where the Group’s companies
have a tradition of more than 100 years in
Switzerland and Germany. In addition, customers benefit from the Group’s cooperation
with trustworthy partners, such as in Turkey
with the large CNC machine provider Form
Makina. And so UNITED GRINDING customers in Europe always find good service: from
Ireland in the west to the far east of Europe.

34

Motion 02.2022

TURKEY“OUR WORLDWIDE NETWORKLETS US QUICKLY AND
COMPETENTLY SERVE OUR
CUSTOMERS.”Paul Kössl,Head of Business Development & Marketing
UNITED GRINDING GroupMÄGERLEBLOHMPRECISION AND QUALITY
UNITED GRINDING machines enjoy an
excellent reputation all over the world

Illustration: pytyczech/Alamy; Photos: Thomas Eugster, Jonas Weinitschke/Shutterstock, Sean Kuriyan, Daniel Vogel, Marek Rucinski, Michael Parulava/Unsplash

SWITZERLAND

JUNGSTUDERSCHAUDT>1000

MIKROSAWALTER

EWAG> 20

EMPLOYEESLOCATIONS AND REPRESENTATIONS

ensure the customer successin Europefor the UNITED GRINDING Grouparound the world

GERMANYIRPDCZECH REPUBLICHISTORY OF GRINDINGTECHNOLOGY LEADER

BASE

9:30 A.M.

10:15 A.M.

10:45 A.M.

QUALITY, TRADITION, AND MODERNITY:
that’s what Switzerland stands for likeno other country. It is thus fitting that
the UNITED GRINDING Group makes its
administrative headquarters in the capital city of Bern. After all, the oldest company in the group was founded here in
the canton when Fritz Studer opened
his small workshop in 1912. STUDER
has since grown into an international
company with several hundred employees and over 24,000 systems installedworldwide. MÄGERLE in Fehraltorf and
EWAG in Etziken also have decades of
tradition and are today one of the mostrenowned names in the machine toolindustry. IRPD, a pioneer in additive
manufacturing in St. Gallen, is also partof UNITED GRINDING.

THE UNITED GRINDING GROUP ALSO HAS
OVER 100 YEARS of GRINDING history inGermany. BLOHM was founded in
Hamburg in 1924, JUNG in Berlin in
1919, and WALTER in Düsseldorf in
1919. Like their Swiss sister companies,
these names have become an integral
part of the machine tool industry, anddeveloped in some areas, into international technologyleaders, for example,
BLOHM in the manufacture of aircraft
turbines. It is therefore not surprisingthat the German UNITED GRINDING
companies have already delivered
several tens of thousands of systems
worldwide, and continue to serve thosecustomers with a competent service
network.

BACK IN 1996, WALTER founded a large
branch in Kuřim, near the Czech metropolis of Brno. Today, components fornumerous machines of the UNITED
GRINDING Group are manufactured
here. Several hundred employees workin one of Europe’s most modern machine tool production facilities and benefit from excellent career and continuing professional development opportunities. Multiple investments have been
made to expand and modernize the site,
including the 2014 expansion of mechanical precision manufacturing andthe construction of a 2,500-squaremeter assembly and logistics building(2017). In the end, everyone benefits:
the customers, the employees, andthe company.

10:45 A.M.

ISTANBUL, TURKEY

STRONG PARTNER
WITH AROUND 10,000 CUSTOMERS, the
CNC retail chain Form Makina is oneof the largest in Turkey and is a strong
partner of the UNITED GRINDING
Group. The company, which was
founded 30 years ago, is headquartered in Istanbul, with branches inmany other Turkish cities as well.

“WE HAVE BEEN WORKINGWITH THE UNITED
GRINDING GROUP IN OUR
COUNTRY FOR 16 YEARS.”
Muhterem Sanko,
Managing Director of Turkish CNC
company Form Makina

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35

UNITED GRINDING GROUP~20

INTERNATIONAL

>250

YEARS

EMPLOYEESUNITED GRINDING present
in China

work every day for UNITED
GRINDING in Asia

T
O
P

3

IN INDIAin the imported machine tools
segment

UNITED GRINDING
IN ASIA
ASIA, THE WORLD'S MOST POPULOUS CONTINENT WITH ROUGHLY 4.6 BILLION INHABITANTS,
is naturally also an important region for UNITED
GRINDING. Our largest location is China, with alarge production hall in Shanghai and a facility inBeijing. The company today enjoys a strong
market position in the mid- and high-end sector
thanks to many years of dedicated customer
care, explains Rain Zhang, head of surface &profile grinding sales.
This same philosophy is also pursued several
thousand kilometers further south at UNITED
GRINDING India. There are 18 employees working at the headquarters in Bengaluru in the stateof Karnataka – and almost all of them speak
several languages. “It’s a country with a wide
variety of cultures and over 100 languages
spoken,” says President C.R. Sudheendra.

JAPANThe third important headquarters of UNITED
GRINDING is located in Asia many thousandsof kilometers further east: Japan. Due to its
great demand for machines tools for fields likethe automotive industry or toolmaking, thehigh-tech country is a very important market —and home to a highly competitive market withnumerous international and domestic manufacturing companies. UNITED GRINDING has
successfully earned a stable market share inthis environment.

CHINA

INDIA

SINGAPORE

9
BRANDSMÄGERLE, BLOHM, JUNG,STUDER, SCHAUDT, MIKROSA,WALTER, EWAG and IRPD arefound around the world, helping
make customers successful

36

Motion 02.2022

MÄGERLE

BLOHM

JUNG

India has 22 official

STUDERSCHAUDTLANGUAGES,TIMELINESS

with well over another 100 unofficial ones

is highly valued in JapanINDIA

MIKROSAWALTER

EWAG

IRPD

30

NATIONALITIES
working together at
UNITED GRINDING

SINGAPOREREGIONAL
EXPERIENCEQUALITY MATTERS

3:30 P.M.

4:00 P.M.

“UNITED GRINDING
MACHINES HAVE BEEN
PRESENT IN INDIA FOR
A LONG TIME, HELPING
MAKE OUR CUSTOMERSSUCCESSFUL.”
C. R. Sudheendra,
President of UNITED GRINDING India

UNITED GRINDING INDIA was founded in
2007, and recently expanded as a joint
venture with Francis Klein, which has
70 years of experience in the sales andmanufacture of high-precision machines
in the region. UNITED GRINDING
machines have also long enjoyed an
excellent reputation in the country
thanks to its sales partners.

Illustration: pytyczech/Alamy; Photos: Jovyn Chamb, Swapnil Bapat, Edward He, David Edelstein/Unsplash

CHINA

BIG IN CHINA
5:00 P.M.

THE LARGEST LOCATION IN ASIA of the
UNITED GRINDING Group is China,
with two large branches in the capital Beijing and Shanghai, the largest
metropolis in the country. Roughly 200
employees in China are hard at work
ensuring the success of our customers — through competent advice andtop-notch technical service.

THE CITY-STATE OF SINGAPORE, the headquarters of WALTER EWAG Asia Pacific,
is conveniently located on the maritime
route between China, Japan, and Europe. The Asia-Pacific region (excluding
China) is managed from here, including
Japan, Taiwan, and South Korea. Customers of STUDER can also rely on
excellent service from distribution
partner DKSH.

JAPANIN THE HEART OF
THE COUNTRY
5:30 P.M.

SINCE UNITED GRINDING JAPAN has
grown organically from two components(STUDER and WALTER/EWAG), there
are also two locations. In the capital
city of Tokyo, the focus is on STUDER
installations, while BLOHM, WALTER
and EWAG customers are serviced fromthe southern Japanese city Anjō in the
Chūbu region.

“OUR RECIPE FOR
SUCCESS LIES IN OUR
CLOSE TIES TO OUR
CUSTOMERS BECAUSEWE MAINTAIN CONTACTOVER YEARS.”
Rain Zhang,Head of Surface & Profile Grinding
Sales UNITED GRINDING China“CUSTOMERS IN JAPANARE DEMANDING AND
EXPECT THE BESTQUALITY ANDTECHNICAL SERVICE AT
THE HIGHEST LEVEL.”
Jun Ikeda,
President WALTER EWAG Japan

Motion 02.2022

37

UNITED GRINDING GROUP

INTERNATIONAL

10,200 m2

1984

ALMOST 40 YEARS OF QUALITYCOMMUNITY

The new head office built in Miamisburg, Ohio in 2017,
represents the strong market position in the region

UNITED GRINDING North America
was founded in 1984

UNITED GRINDING is a good corporate citizen in
North America, offering scholarships and events

OF SPACE

CANADAOUR PARTNER IN
CANADA
11:30 A.M.

HIGH-PRECISION PRODUCTION SOLUTIONS
are the specialty of Machine Tool Systems, the UNITED GRINDING Group’s
trusted partner in Canada. Founded in
1998, with locations in the cities ofToronto and Montreal, the company ismanaged by President John Manley andoffers customers of MÄGERLE, BLOHM,
STUDER, WALTER and EWAG competent advice and expertise in purchasing,installation, maintenance, and service.

CANADAUSAMEXICOUNITED GRINDING’S
SUCCESS is made possible

BRAZIL

38

Motion 02.2022

by the commitment anddedication of its employees —modeled by Hans Ueltschi,
who was on hand at the first
North American site in the eighties. To provide the quickest possible
help to a customer whose machine
tool had failed, the young technician
rented a single-engine Cessna and flew withhis colleague Nick Schuetz to Norwood Airport
in the state of Massachusetts. Today, Ueltschi isvice president sales cylindrical division.

MÄGERLE

BLOHM

200

EMPLOYEES
work for UNITED GRINDING
North America

STUDERSCHAUDT

60 % of the machines installed
by UNITED GRINDING in North America can bereached from Miamisburg by car in no morethan five hours

USA

Illustration: pytyczech/Alamy, Photos: Don Mammoser/Shutterstock, Bruno Soares, Stephan Cassara, Laurentiu Morariu, Agustin Diaz Gargiulo/UnsplashJUNG

MEXICOMIKROSAWALTER

EWAG

IRPD

WIN-WIN

SYMBIOTIC SUCCESS
Customer success is always shared by
UNITED GRINDING, and vice versa

BRAZILHEADQUARTERS INNORTH AMERICA

BRIDGE TO LATIN
AMERICA

TRUSTED
COOPERATION

NOON

12:30 P.M.

1:00 P.M.

UNITED GRINDING NORTHAMERICA’SMODERN HEADQUARTERS were built only
five years ago and offer 10,200 m2 for
production, development, service,
sales, and office space. In total, morethan 200 employees work to ensure
customer success in North America.
Things started much more humbly in
1984, under the name Hauni-BlohmSchaudt in the east coast American
state of Virginia. The employees’
tremendous dedication has brought thecompany to a strong market position,
where it can quickly reach customers in
the USA and Canada from its centrally
located Miamisburg, Ohio facilities.

WITH A STRONG PRESENCE in Mexicoand several employees, UNITED
GRINDING supplies customers in Latin
America with machines and systems
from all the Group's brands and provides services such as maintenance,
repair, and consultation. The city ofSantiago de Querétaro in the state of
the same name is ideally located toreach various regions quickly.

ON THE BRAZILIAN MARKET, UNITED
GRINDING customers can rely on thecompetent service of the machine
specialists at Tecno-How with locations
in Valinhos and São Paulo. The
company, which focuses on SouthAmerica, specializes in high-quality
systems and complete solutions forstate-of-the-art manufacturing in theautomotive, aerospace, medical, andenergy sectors. The strong partnershipwith UNITED GRINDING has been inplace since 2017. The expert technicalstaff delivers customer support,
technical advice, and training.

“FROM MIAMISBURG, WE CANOPTIMALLY COVER THE MARKET FOR
CYLINDRICAL, SURFACE, PROFILE
AND TOOL GRINDING MACHINES IN
THE USA AND CANADA.““MASS-PRODUCED COMPONENTS OR
HIGH-MIX, LOW-VOLUME PRODUCTION:
UNITED GRINDING CAN SATISFY ANYREQUIREMENT AND HELP OVERCOME
CHALLENGES.“

Jacob Baldwin, Director of Corporate Marketing
UNITED GRINDING North America

German Gordillo, Managing Director
UNITED GRINDING Mexico

Motion 02.2022

39

UNITED GRINDING GROUP

40

Motion 02.2022

IDEASMÄGERLE

BLOHM

JUNG

STUDERSCHAUDTMIKROSAWALTER

EWAG

IRPD

BETTER DATA FOR
INDUSTRY
The collection and evaluation of large quantities of data (Big Data)enable more targeted decisions toward increasing operational efficiency.
But the potential has not yet been fully tapped

Photos: Audio und Werbung/Shutterstock, Science History Images/Alamy

TEXT:Philipp Gölzer

IT WAS ALMOST EXACTLY 100 YEARS AGO THAT the
first car rolled off the assembly line. The Ford
Model T was revolutionary not just as a
product, but also for the industrial production that went into it. Around 15 million units
were produced for the mass market in theUSA. Even back then, data played an important role: Quantities produced, employee hours, raw materials consumed, rejects,
delivery times, prices, and many other factors were of interest to Henry Ford, a famously clever businessman. He ensured
that they were regularly reviewed to optimize production. By the time they ended
production of the vehicle, assembly times
for one vehicle had fallen to roughly one anda half hours instead of twelve.
In this early phase of industrialization,
the number of units produced in particular
was an important parameter. If the daily target was missed, then a great deal of time
was spent trying to determine why. Thanks
to comprehensive sensor technology andnetworking, industry can now access infor-

mation about all processes in real-time and,if necessary, take corrective action. Every
forklift, every robot, every machine tool andmany other components in a modern production facility can be part of this network.

MACHINES COLLECT DATA VIA STATEOF-THE-ART SENSOR TECHNOLOGY
The advantages are obvious: The status andprogress of an order can be viewed in real-time. Instead of waiting until the end of aday or week, producers know at all times
whether or not there is a problem with anorder, and can take appropriate measures invery short cycles. Or, if the data provided by
Logistics suggests a problem with the delivery of raw materials or components, produc-

Left picture: This is what a quantum computer
looks like, a new technology that could
revolutionize our ability to interpret datation can be changed to prioritize available
components. In addition, analyzing processdata allows manufacturers to improve efficiency continuously. Are there deviations in
the temperature of a machine? Is there an
unusually large amount of rejects? Is energy consumption within expected limits?
These and other questions can be answeredby machine learning based on the collected
process data. Without consistent data collection and corresponding evaluation, it ishardly possible today to increase the performance, process quality, and automation ofindustrial production.
However, digitization of industrial processes is not a blueprint. Rather, each company must develop its strategy adapted tothe product, working method, supply chains,and competitive situation. In addition to specific production processes, questions suchas: Should production be as cost-effective
as possible in a fiercely competitive environment? Or is does achieving the highest possible quality matter first and foremost? Or is
Motion 02.2022

41

UNITED GRINDING GROUP

IDEAS

175,000,000,000,000

GIGABYTESIn 2025, the global data volume will be 175 trillion gigabytes (175 zettabytes).
A modern car produces around 600 gigabytes per day

CO2neutrality at the forefront? Depending on
the objectives of the company, it is necessary to develop specific use cases and to collect and evaluate the necessary data.

track of such quantities, modern hardware
and software can visualize, classify, and categorize them, recognize patterns and structures, and create forecasts based on them.

THE LIMITS OF TODAY’S AI

INDUSTRY NEEDS TO COLLECT MORE
RELEVANT DATA

One aspect that must never be overlookedin these considerations is IT security and data protection. Although personal data is generally not exchanged between providers andcustomers, process data is. If you want tobenefit from the advantages of modern software and higher efficiency, networking anddata exchange across the value chain are
essential. Remote maintenance and regular
updates are also major advantages of modern machines. In principle, companies have
two options here: setting up their own servers and cloud services with appropriate protection or using open cloud systems, suchas those from Amazon or Microsoft. In any
case, trust between providers and customers and transparency in communication areimportant.
But at this point, we have to ask ourselves: What is already possible right now interms of data analysis, and what are the limits? Clearly, the progress made in the areasof artificial intelligence (AI) and machinelearning is breathtaking. A modern car is estimated to generate more than 600 gigabytes
per day, with global data volumes expected
to exceed 175 trillion gigabytes in 2025, according to a study by the International Data
Corporation (IDC). While nobody can keep
42

Motion 02.2022

For example, an AI application today canmost likely predict whether a workpiece thatis still in production will end up as a reject.
Another might provide information on whichmachine parameters can be used to produce
a workpiece in a more energy-efficient manner. This is impressive, but it shows the limit of today’s AI: It deals with small-granular
issues and often requires humans as the final decision-making body. Higher-level

ABOUT
PROF. PHILIPP GÖLZER
Philipp Gölzer is the Business Area Coordinator for Digitized Production at the Fraunhofer
Institute and Professor of Digital Factory andMaterial Flow Systems at
TH Nuremberg. He wrote
his dissertation on the
topic of Big Data inIndustry 4.0.

questions of an overall process chain cannot yet be supported or optimized with AI.
R&D aims to develop more robust AI applications that answer operational questions
and implement autonomous decisions
based on them. In addition to the corresponding quality and quantity of the underlying data, this requires high-performancedata processing. The latter is opening up
new dimensions thanks to the developmentof quantum computers.
To date, industrial data has been generated primarily as a “waste product” of existing operational application systems (e.g.
PLC, MES, ERP), whose primary task is theplanning and control of productive operations; for example, sensor data (temperature,
speed), transactional data (production orders, transport orders), or master data (material, work plans).
However, for high-performance AI applications, the processes must be reconsidered and redesigned from the perspectiveof AI data requirements. Which data is required in which quantity and quality in order to implement specific use cases? With
such data, it will be possible in the future tocreate comprehensive and individual profiles for machines, including their strengths
and weaknesses for certain situations andtasks. Ultimately, advances in AI will freepeople from routine activities and enable
them to use their cognitive skills more intensively to optimize and innovate processes and products.

MÄGERLE

BLOHM

JUNG

STUDERSCHAUDTMIKROSAWALTER

EWAG

IRPD

LARGEST SHOW
FOR MACHINETOOLS IN CHINAAPRIL 10–15, 2023,
BEIJING, CHINA

FOR MANY YEARS, THE CHINA INTERNATIONAL MACHINE TOOL SHOW (CIMT) has
been the most important show for
machine tools in the country andone of the largest in the world. The
UNITED GRINDING Group will be
represented at the international exhibitioncenter in Beijing (ShunyiHall) in April, where CIMT will be held for the 18th time. A total of
1,500 exhibitors from 27 countries and regions are expected, presenting their latest products and technologies in the approximately 140,000 square meters of exhibition space. The most recent
show in 2021 attracted an industry audience of more than
122,000 visitors. The UNITED GRINDING Group’s exhibition area
is led by UNITED GRINDING China, which serves customers of all
brands within the Group from two large locations in Beijing andShanghai. One focus at CIMT is current technologies in the fieldof metalworking machine tools, as is measurement and laser
technology, as well as new automation and software solutions.
The UNITED GRINDING Group and its companies are innovation
leaders in many of these fields, and look forward to direct
exchange with experts and show visitors.
18th China International Machine Tool Show (CIMT), April
10–15, 2023, Beijing, China, www.cimtshow.com

EXHIBITION CALENDAR:JANUARY 2023
JANUARY 19–25, 2024
IMTEX –BENGALURU, INDIA

MARCH/APRIL 2023
MARCH 30–APRIL 1, 2023
MECSPE –BOLOGNA, ITALYAPRIL 2023
APRIL 10–15, 2023
CIMT –
BEIJING, CHINA

MAY 2023
MAY 9–12, 2023
CONTROL –STUTTGART, GERMANY
MAY 15–19, 2023
LIGNA –HANNOVER, GERMANYYOU CAN FIND THE LATEST
TRADE SHOW DATES AT:
www.grinding.ch/en/events

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43

UNITED GRINDING Group
3014 Bern, Switzerland
T +41 31 356 01 11
grinding.ch

SURFACE AND PROFILECYLINDRICAL

TOOLMÄGERLESTUDERWALTERWALTER EWAG

8320 Fehraltorf, Switzerland
T +41 43 355 66 00
maegerle.com

3602 Thun, Switzerland
T +41 33 439 11 11
studer.com

72072 Tübingen, Germany
T +49 7071 9393 0
walter-machines.com

Anjo City 446-0056, Japan
T +81 556 71 1666
walter-machines.com

BLOHM JUNGSTUDERWALTERWALTER EWAG

21033 Hamburg, Germany
T +49 40 33461 2000
blohmjung.com

2504 Biel, Switzerland
T +41 32 344 04 50
studer.com

30827 Garbsen, Germany
T +49 5131 4948 0
walter-machines.com

609916 Singapore
T +65 6562 8101
walter-machines.com

BLOHM JUNGSTUDERWALTERWALTER EWAG

73037 Göppingen, Germany
T +49 7161 6271 800
blohmjung.com

Tokyo 143-0016, Japan
T +81 3 6801 6140
studer.com

66434 Kuřim, Czech Republic
T +420 541 4266 11
walter-machines.com

SCHAUDT MIKROSA

EWAG

Warwick CV34 5DR,
Great Britain
T +44 1926 4850 47
walter-machines.com

73037 Göppingen, Germany
T +49 7161 6271 815
schaudtmikrosa.com

4554 Etziken, Switzerland
T +41 32 613 31 31
ewag.com

WALTER EWAG

22070 Bregnano (CO), Italy
T +39 31 7708 98
walter-machines.com

UNITED GRINDING GROUP INTERNATIONALUNITED GRINDING

UNITED GRINDING

UNITED GRINDING

IRPD

Shanghai 201814, China
T +86 21 3958 7333
grinding.cn

Bangalore 560058, India
T +91 80 30257 612
grinding.ch

Miamisburg, OH 45342, USA
T +1 937 859 1975
grinding.com

9014 St. Gallen, Switzerland
T +41 71 274 73 10
irpd.chUNITED GRINDING

UNITED GRINDING

UNITED GRINDING

Beijing 100015, China
T +86 10 8526 1040
grinding.cn

119334 Moscow, Russia
T +7 495 956 93 57
grinding.ch

Querétaro, Qro. 76090, Mexico
T +52 4421 99 5010
grinding.com