Spotlight on energy and resource consumption at GrindingHub.

Even before the start of the Russia-Ukraine war, rising energy costs were putting pressure on the manufacturing sector. Germany has long had the highest prices for industrial electricity in Europe. At the same time, all companies are being called upon to reduce their carbon emissions significantly and ensure that their production is resource efficient. Grinding is no exception here. Industry experts are actively looking at how to reduce energy and resource consumption all along the process chain – including at the recent digital “Schleiftagung” grinding conference of the Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University and at the GrindingHub trade show in Stuttgart in May.

Rising energy and raw material costs, legal regulations and extended customer requirements are all significant factors which are increasing the importance of energy efficiency in grinding. Within the process chain, grinding is considered an energy-intensive manufacturing process, since comparatively small workpiece volumes are machined at relatively high cost. However, LCA improvements are anything but trivial, and can often only be achieved in small steps or on the periphery of the production operation itself.

Thinking beyond the grinding process

Prof. Thomas Bergs, Executive Director of the WZL and member of the WGP (German Academic Association for Production Technology) introduced a further aspect in his presentation at the grinding conference. He pointed out that grinding technology can make a significantly greater contribution to climate protection and resource conservation if companies are prepared to think beyond the actual grinding process. Optimizing the CO2-optimized design of the grinding process also includes considering the optimized function of the component in use. More efficient process control leads to reduced use of resources not only in the manufacturing, but also in the service phase of the workpiece by ensuring longer service lives and improved functional properties. This requires recording the use of energy and resources for each component in digitally networked production.

For Thomas Bader, Managing Director of Haas Schleifmaschinen GmbH in Trossingen, Baden- Württemberg, improving energy and resource efficiency therefore starts well before the actual grinding process: it begins in the selection of appropriate materials for the construction of the machines. In its Multigrind machines, for example, Haas has opted for a mineral cast machine bed which not only uses 30% less energy in production but is also particularly durable and easily recyclable. In addition, mineral cast beds offer excellent vibration damping, which increases the service life of tools. If tools – in this case grinding wheels – must be dressed less frequently, this has a positive effect on the energy footprint, says Bader.

Recyclability plays a major role in machine design, emphasizes the Haas manager, as do the requirements of the European RoHS Directive for electrical and electronic equipment. This stipulates that every component must be subjected to a risk assessment for environmentally hazardous substances. "Smart savings" is the watchword when it comes to measures that help reduce energy consumption in machines, says Thomas Bader.

Machines, grinding oils and grinding wheels

There are numerous examples of effective measures. Bader cites energy recovery modules which recuperate the energy of the NC axes and grinding spindles during braking, and the use of economical synchronous motors. Haas Schleifmaschinen also makes use of the intelligent Ecomodus standby concept. This is based on software that reduces power consumption in standby mode by a further 70%. The grinding machine manufacturer is also dedicated to minimizing the use of lubricants. For example, the company’s own linear axes rely on the use of economical grease lubrication instead of oil mist. The supply of energy-optimized cooling lubricant (coolant) is provided in a controlled pump operation using 3D coolant shaped nozzles specifically adapted to the workpiece.

The ways in which coolants and grinding oils can influence energy efficiency in the grinding process are explained by Ken Bausch, grinding oil expert at oelheld GmbH. The company is committed to sustainability in the development of its products, production processes and its use of resources - as expressed through its own Hutec (Human Technology) brand for humans, nature, and machines. The Stuttgart-based company decided at an early stage to purchase its own machines, which would allow it to carry out test series itself. Analysis and testing equipment can now be used to determine the optimum type of oil based on a finely tuned ratio of viscosity and additives for every machine type and every grinding process, says Bausch. The results include not only long service lives and low refill quantities for the oils, but also quiet, smooth, and easy running of the machines, which is indispensable for achieving fast machining, low tool wear, superior surface qualities and economical power consumption. "We are meeting very clearly expressed customer demands here," says Bausch.

New materials posing new challenges

According to Bausch, these new and in some cases exotic materials that must be processed will present major challenges in the future – and thus new tasks for the research and development department at oelheld. "We are gliding into new areas together with the machine manufacturers," says the expert. He is also expecting to receive corresponding inquiries at GrindingHub. Furthermore, oelheld is cultivating partnerships with universities and research institutes in response to new technological requirements.

Similarly, the trend toward high-strength materials which are difficult to machine is likely to frustrate efforts to increase energy and resource efficiency, especially given the simultaneous calls for process-reliable manufacturing plants capable of 24/7 production. "The only way to improve energy efficiency in the grinding process is to find a perfect match between the machine, workpiece, grinding wheel, dressing tool, dressing spindle and cooling medium," says Christoph Müller, Head of Application Technology at Dr. Kaiser Diamantwerkzeuge GmbH & Co. KG, system provider for grinding technology, based in Celle, Lower Saxony. As a rule, the customer's primary focus is on the component being manufactured, he says. The process of dressing the grinding wheel responsible for carrying out the actual manufacturing process is regarded as non-productive time. Thus, the experts at Dr. Kaiser have the task of conditioning (profiling and sharpening) the grinding wheel in the shortest possible space of time.

Individual limits for process optimization

During process optimization, all parameters, especially cutting speed and feed rates, must be optimized before the dressing tool can be adjusted accordingly. However, it should be borne in mind, says Müller, that each production machine has its own physical limits within the process. Here, he says, it is often necessary to rely on empirical values. Nevertheless, about 80 percent of the optimization potential can be determined by making prior process calculations.

The grinding wheel itself offers optimization potential in terms of cycle time, as it can be trimmed not only for faster grinding but also for a longer tool life. After the unavoidable dressing process to condition the grinding wheel, it will be able to grind stably for longer and create more workpieces until it needs to be dressed again due to grinding wheel wear, abrasion, clogging or loss of shape. According to Müller, Dr. Kaiser is contributing to sustainability with its in-house ECO change system, which will also be on display at GrindingHub. Here, the carrier unit can be used several times; only the diamond coating (which wears out over time in the dressing process) is replaced. This saves more than 80% of material and energy compared to conventionally manufactured dressing tools.

Durability is key factor in resource conservation

For grinding oil manufacturer oelheld, improving energy efficiency involves creating durable products, ensuring superior quality levels, and using high-grade raw materials, emphasizes Ken Bausch. Durability is also the key to resource-saving production for Thomas Bader, Managing Director of Haas Schleifmaschinen. For him it is vital to ensure that the manufacture and use of the company’s Multigrind machines are as environmentally friendly as possible. This includes advising customers on how to obtain the longest possible use of their machines. A lifetime of 30 years is not unrealistic, he says. "It often makes more ecological sense to give machines that are not in continuous use a general overhaul with new components and thus breathe a second life into them than to advise customers to buy new equipment," Bader notes.

At GrindingHub, Haas Schleifmaschinen will present its first ever Multigrind system in which the machine and control are separate. The machine is controlled via a tablet which can be replaced if the operating system is no longer receiving updates or if a fault develops. In this way, machines can continue to offer a long service life even in these times of fast-moving digitalization and increased networking. It is important to think beyond the grinding process itself.

The 2-year program starting with a 12-week immersive introduction to the industry that merges hands-on training and repair of CNC machines with classroom training.

Hurco North America will open applications for the third class of its apprenticeship program April 1. The Field Service Apprenticeship (FSA) is a 2-year program starting with a 12-week immersive introduction to the industry that merges hands-on training and repair of CNC machines with classroom training.

While candidates with a degree or working toward one are encouraged to apply, candidates who are mechanically inclined with no industry or engineering experience are also encouraged to apply for the FSA.

“We know there are people outside our industry who would excel at a career as a service engineer for machine tools, but might not have been exposed to our industry," says Cory Miller, General Manager for Hurco North America. "We believe the FSA will be important to bridge the skills gap and introduce more people to the machine tool industry, which benefits the industry as a whole.”

Field service engineers will ultimately be ambassadors for Hurco Companies, Inc. working to provide technical support, training, and service of state-of-the-art CNC machines at customers’ facilities across the country. Continuous training on emerging technologies in CNC controls, robot integration, 5-axis machine and multi-spindle lathe installation, repair, and applications will also be provided long after completion of the apprenticeship.

“If you have a strong work ethic, like to learn how things work, like hands-on training, and want a career instead of a job, this apprenticeship is for you,” says Mark Gilmore, Service Manager for Hurco North America.

The FSA program takes place at Hurco’s headquarters in Indianapolis, Indiana. To apply, please visit Hurco.com/FSA.

Wohlers Report 2022 shows AM industry growth of 19.5% in 2021. This is up from 7.5% growth in 2020, which was impacted greatly by the pandemic.

Wohlers Associates, powered by ASTM International, published the Wohlers Report 2022, the 27th consecutive year of publishing the industry-leading annual report. It provides new content and expert analysis on additive manufacturing (AM) and 3D printing.

Research for Wohlers Report 2022 shows AM industry growth of 19.5% in 2021. This is up from 7.5% growth in 2020, which was impacted greatly by the pandemic.

“As expected, the industry has returned to a period of advancement and investment,” said Terry Wohlers, head of advisory services and market intelligence at Wohlers Associates, powered by ASTM International. “This expansion cuts across aerospace, healthcare, automotive, consumer products, energy, and other sectors.”

Among the new and expanded features of Wohlers Report 2022:

Wohlers notes that Wohlers Report 2022 provides readers with a competitive edge through insight, analysis, trends, and forecasts. It serves as a tool for decision making and knowledge acceleration. The foundation of the 425-page report is 26 years of data and market intelligence, coupled with a vast network of contacts worldwide.

As the technology and industry mature, a growing number of companies are using AM for custom products and series production, according to the new report. A sign is the growth of polymer powder consumption in 2021, which grew by 43.3% to overtake photopolymers as the most used AM material, Wohlers Report 2022 shows. 

The report includes details on 147 early-stage and corporate investments, and 75 mergers, acquisitions, and initial public offerings.

Join us on March 31 as we close out Women's History Month with a webinar roundtable featuring women to watch in manufacturing.

Per the U.S. Department of Commerce, although women represent about 47% of the total workforce, they only make up about 30% of the 15.8 million people employed in manufacturing industries. Furthermore, only 1 in 4 manufacturing leaders are women, so the topic of diversity, equity, and inclusion are top of mind for many.

To learn the latest thoughts from women in manufacturing, join Elizabeth Engler Modic as she moderates a roundtable discussion on Thur., March 31 at 12PM ET, with leading women involved in manufacturing. Panelists include Dr. Heike Wenzel, CEO of WENZEL Group; Veronica Messersmith, Vice President of Strategic Relations, Americas at Sandvik Coromant; and Alyssa O’Brien, Product Engineer with OSG USA.

Don't delay, secure your registration here.

Ribbon-cutting ceremony held after 2-year delay celebrated new lab space for engineering students.

Nordson Corporation publicly celebrated its sponsorship of the new Nordson Innovation Lab in the ViaSat Engineering Pavilion, California State University at San Marcos, during a ribbon-cutting ceremony this March. The CSUSM campus is located near Nordson Electronics Solutions facilities, where equipment used in electronics manufacturing is designed and built.

CSUSM’s focus on student success and social mobility for first-generation college students and a diverse student population is closely aligned with the goals of the Nordson Corporation Foundation, the philanthropic arm of the company. Nordson donated $100,000 in 2019 to help fund the renovation of an existing building.

“A big thank you to Nordson Corporation for partnering with California State San Marcos on helping our students achieve success,” says Ellen Neufeldt, CSUSM President. “Building engineering at CSUSM has been, from the start, about creating the very best program possible to help foster a diverse talent pipeline.”

“We look forward to seeing how it benefits engineering students from a wide range of backgrounds,” states Sara Vaz, community relations manager, Nordson.  “And we are pleased to finally celebrate after such a long delay.”

The new lab’s opening had been planned for March 2020 but when the pandemic occurred, the ceremony was postponed. From August 2020 until June 2021, the space was used by San Diego County as a walk-up COVID-19 testing site.