High-tech for the finishing touches - METAV 2012 is a forum for grinding technology

Frankfurt am Main, 15 December 2011. – The sheer diversity of the jobs involved is enormous: they range from forming, decorating glass, sharpening tool edges all the way through to fine-cutting processes for microscopic examinations. No wonder that the subject of grinding will be playing an important role at the METAV 2012 in Düsseldorf from 28 February to 3 March, as indeed it does at the prestigious Machine Tool Laboratory (WZL) in Aachen.

Surprisingly enough, some production experts treat grinding as a sot of poor relation, even though it is crucial to a component’s quality. One man who knows and appreciates the process’s value is the engineering graduate Markus Weiss, who heads the Grinding Technology Group at the Faculty of Production Process Technology at the Machine Tool Laboratory (WZL) of RWTH Aachen University. “We are seeing more and more inquiries about grinding high-strength nickel-based materials, plus titanium and carbon-fibre-reinforced plastics”, says the expert. He also sees a lot of potential, though, for tools with a defined edge or for milling cutters, inserts or drills. Particular know-how was required when it came to optimising a production process for a rather special tool. To quote Markus Weiss: “We’re talking here about new, patented ceramic materials based on zirconium oxide, which are used for making eyes scalpels for operating on diseases like cataracts. It’s a cost-efficient alternative to the scalpels made of steel or diamond that are otherwise used.”

Grinding in XXXL format

Ultra-stringent requirements are encountered not only in the field of medical technology (five-axis machining, for example, of implants made from ceramics, plastics or titanium), but also in sectors like energy engineering (for example: gear wheels and bearing components). Processes for high-performance grinding are particularly sought after. The Machine Tool Laboratory, for example, has done crucial work in helping to design-enhance speed-stroke grinding (table feed rate up to 200 m/min.; maximum table acceleration 50 m/s²). This flat-grinding process is suitable for jobs like machining turbine blades. On the scientific side, the laboratory staff in Aachen have most recently been studying vibratory grinding, a technique for surface finishing. To quote Markus Weiss: “The process is suitable for deburring and improving the surface quality.”

Energy-economy is exerting an ever-greater influence on the experts’ work: the staff in Aachen are with this in mind optimising what have up to now been very high consumption levels of cooling lubricant. Markus Weiss has obtained good results with ester-based cooling lubricants, which “in terms of performance capabilities mostly do rather better than conventional lubricants based on mineral oil”. His group is also engaged in a special research project, shared by the Universities of Applied Science in Dresden and Chemnitz, to study the thermal behaviour of machine tools. “We’re taking a long hard look at how the heat produced during the grinding process affects the machine’s structure and the component’s quality”, he explains.

Base body made of carbon-fibre-reinforced plastic for high-speed jobs

For the grinding disks, Markus Weiss has observed an ongoing trend towards using carbon-fibre-reinforced plastics as a material, employed for the base body in place of the classical materials like steel, ceramics or aluminium because they permit higher circumferential grinding velocities of up to 250 m/s. “It’s question of calculating the cost-efficiency, where the factors involved include quantities, wear and tear, and materials”, explains Markus Weiss. “So it’s quite possible that a conventional disk is the more cost-efficient alternative.”

But how does the grinding expert rate competing processes like laser-assisted turning, which the Aachen-based Fraunhofer IPT has developed in conjunction with the machine tool manufacturer A. Monforts Werkzeugmaschinen GmbH & Co. KG from Mönchengladbach for machining harder materials like ceramics or hard-metal? “Grinding always gets done somehow”, is his diplomatic answer. “But process combinations of this kind can definitely make sense in terms of both engineering and cost-efficiency.” To make sure that everything is viewed with a wider focus than a specialised expert’s, the Machine Tool Laboratory has recently set up a new unit called the Technology Planning Group, which examines the advantages and disadvantages of all the production processes involved.

The scientist will be looking for input across the entire gamut of all processes at the METAV 2012. “We shall definitely be going to the fair with our group, to take a good look at the grinding technology on show there”, comments Markus Weiss. “What’s more, the METAV also offers a very good atmosphere for entering into cross-technology conversations.” A wise decision, since around 40 manufacturers of grinding, honing and finishing machines will be among the exhibitors in Düsseldorf – but manufacturers like Monforts will also be showcasing new, competing processes at the fair.

Author: Nikolaus Fecht, specialist journalist from Gelsenkirchen

Pictures in a printable version are available at www.metav.de/photos

Overview pictures

For background:
WZL, Aachen

The Machine Tool Laboratory (WZL) at RWTH Aachen University (720 staff) has for decades now been synonymous worldwide with successful, up-to-the-future research and innovation in the field of production technology. In six research categories, it carries out both basic R&D and research projects focused on the requirements of the industrial sector, as well as creating practicable solutions for streamlining production operations. Grinding is researched by a Grinding Technology Group (ten staff) at the Faculty of Production Process Technology (headed by Prof. Dr.-Ing. Fritz Klocke). Hands-on input from the field has been responsively studied for almost ten years now by the Grinding Technology Working Group, which currently has 28 member firms, who engage with the process as manufacturers and users, and with the new Tool Technology Working Group. The Machine Tool Laboratory communicates its expertise in the field of grinding technology by organising basic seminars. www.basisseminare.de, www.wzl.rwth-aachen.de

METAV 2012 in Düsseldorf

The next METAV will be held from 28 February to 3 March 2012 in Düsseldorf. In the even years, it has firmly established itself as an important technology shop window for the entire gamut of manufacturing technology and automation in Germany for manufacturers and customers from Europe. The METAV will be showcasing the entire spectrum of manufacturing technology, focusing on machine tools, production systems, high-precision tools, automated material flows, computer technology, industrial electronics and accessories. The METAV’s visitor target group includes all major industrial sectors, particularly plant and machinery manufacturers, the automotive industry and its component suppliers, aerospace, the electrical engineering industry, the metalworking sector, medical technology and the craft sector. At the last METAV in 2010, around 700 exhibitors showcased their products, solutions and services on more than 32,000 m² of net exhibition area. They attracted approximately 45,000 trade visitors from 26 different countries.

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Your contact persons:

Machine Tool Laboaratory WZL of RWTH Aachen University
Kurt Rütten
Press and Public Relations Work
Steinbachstrasse 53
52074 Aachen
GERMANY
Tel. +49 241 8079 68
k.ruetten@wzl.rwth-aachen.de
www.wzl.rwth-aachen.de

Werkzeugmaschinenlabor WZL der RWTH Aachen
Faculty of Production Process Technology
Dipl.-Ing. Markus Weiss
Group Leader
Grinding Technology Group
Steinbachstr. 19
52074 Aachen
Tel. +49 241 80281 83
m.weiss@wzl.rwth-aachen.de

Verein Deutscher Werkzeugmaschinenfabriken (VDW)
Sylke Becker
Leiterin Presse- und Öffentlichkeitsarbeit
Corneliusstraße 4
60325 Frankfurt
DEUTSCHLAND
Tel. +49 69 756081-33
Fax +49 69 756081-11
s.becker@vdw.de
www.vdw.de


pm_schleifen_2011_12_eng.doc