Newsletter from DIAMETAL AG 1/16

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For example, several audits carried out by customers in the medical and aviation engineering sectors have shown that we have our workflows and production technology under control.

1 1 09 Newsletter from DIAMETAL AG 1/16 EDITORIAL Dear Business Partners, 2015 has brought about a number of challenges for the Diametal Group. We have taken this situation as an opportunity to further enhance our processes and develop the expertise of our employees. For example, several audits carried out by customers in the medical and aviation engineering sectors have shown that we have our workflows and production technology under control. Our large-scale investments in the latest metrology equipment are paying off two-fold: we are on the one hand able to effectively measure and record all the relevant quality parameters of our products, and on the other hand that's the way and the only way that we can provide the quality our customers demand and do so in a reliable and lasting manner. In addition, we have succeeded in reducing the throughput times for a number of products by up to 65%. In conjunction with our expanded warehouse programme, this means for you esteemed customer a significantly reduced capital commitment and a more flexible planning of your production capacity, and therefore improved economic efficiency for your processes. Specific examples of the further development of our tools in our core fields of competence, namely Swiss-type (sliding head) turning, hobbing, grinding and customised precision parts made of ceramic and carbide materials, can be found once again in this new edition of Diamail. Hopefully, this will give you a few suggestions that you can then implement in your own process improvements and that can stimulate you towards new solutions. We warmly invite you to embark on what we hope will be an entertaining voyage of discovery. With best wishes, Dr.-Ing. Michael Op de Hipt CEO Diametal AG Special electroplated tools are one of the strengths of Diametal Diametal is specialised in the manufacture of precision grinding tools according to specific customer drawings. These tools consist of a high-precision wheel body, which is custom-plated with quality diamond or CBN abrasive grits. In addition, Diametal also offers a large stock range of quality standard products with short delivery times and attractive prices. This group of grinding tools is characterised by an extremely high removal rate and high dimensional stability. The high chip space volume enables an efficient coolant supply directly into the processing area and also offers sufficient space for chip removal. The tools are used in dry as well as wet grinding. There is no need for dressing during the entire service life of the wheel. This avoids downtime and eliminates the need for a dressing device. Worn wheels are provided with new grit in a continuous re-plating cycle. Wheel bodies can generally be reused several times. As such, the tools are ideally suitable for series production. For the plating of wheel bodies delivered to us, the choice of base material, the quality and type of the abrasive grit and the thickness of the abrasive coating are things that should be agreed in advance with the technical personnel at Diametal. DIAMETAL

abrasives The ideal embedding of the grit and harmonisation between the bond and body material are the result of many years of experience in the manufacture and practical application of our tools.

Diamond and CBN are often referred to as "super-abrasives" that can process materials such as: pre-sintered carbide cast metals, ferrites glass, ceramics, porcelain carbon, graphite fibre-reinforced

2 abrasives The ideal embedding of the grit and harmonisation between the bond and body material are the result of many years of experience in the manufacture and practical application of our tools. By optimising the manufacturing process for electroplated bond diamond and CBN grinding tools, we are today able to offer economic grinding process solutions for all kinds of materials. Diamond and CBN are often referred to as "super-abrasives" that can process materials such as: pre-sintered carbide cast metals, ferrites glass, ceramics, porcelain carbon, graphite fibre-reinforced plastics hard metal high-alloy hardened steels HSS steels cast-hardened ferro-titanium alloys iron/nickel/cobalt alloys like alnico and Stellite If you need more information about the field of application for electroplated grinding wheels, please contact our sales advisors. Diametal offers you expert advice and innovative solutions. 2 DIAMAIL 1 16

abrasives The POLISTAR wheel makes your grooves shine For more than 40 years, Carbilly has been able to attest to its skills in the cutting tool manufacture sector, in particular, milling tools.

One of the market requirement for milling tools is obtaining a mirror-bright polished spiral flute.

3 abrasives The POLISTAR wheel makes your grooves shine For more than 40 years, Carbilly has been able to attest to its skills in the cutting tool manufacture sector, in particular, milling tools. From the standard, solid carbide tool to the specific instrument, the company is determined to respond to all its clients requirements, in terms of design, expertise, quality and competitiveness. One of the market requirement for milling tools is obtaining a mirror-bright polished spiral flute. In close collaboration with Diametal s application engineer, Carbilly s operator has developed the optimal grinding process on the Saacke UW1F machine with the POLISTAR wheel, developed specifically for this need. After careful preparation of the abrasive wheel through repeated grooving in solid material, it has been possible to produce PO- LISTAR in several series of 4-lipped milling cutters with Ø10mm at an infeed depth of 2.5 mm and a feed rate of 2.5 mm/min. The wheel can operate in one pass, without a preliminary step and without any re-sharpening or re-profiling of the abrasive wheel. The use of a second wheel for any subsequent grinding with a low plunging depth is not necessary. The POLISTAR wheel alone produces a mirror finish and makes your grooved tools shine. As a result, the cycle time can be significantly reduced without any increase in spindle power. Thanks to the high depth of cut with a fine grit size, the risk of any abrasive traces from prior rough grinding is also eliminated. The POLISTAR line is not only convincing in terms of its cutting efficiency it also has excellent profile stability. This results in an extremely economical operating lifetime for the wheel without it having to be re-sharpened or re-profiled. Advantages of the POLISTAR grinding wheel Just 1 wheel only instead of a pre-grinding and fine-grinding wheel Significant reduction in production time Exceptional quality of the surface finish Ra < 0.05µm The result is impressive: you can see your own reflection in the groove! DIAMETAL 3

hard materials New delivery time for hob cutters of 3 to 4 weeks Diametal has been working for several months at all levels to reduce the delivery times for hob cutters.

4 hard materials New delivery time for hob cutters of 3 to 4 weeks Diametal has been working for several months at all levels to reduce the delivery times for hob cutters. Various measures have been implemented to achieve this, which take effect at all stages from the receipt of the order through to the dispatch of the milling tool to the customer. Firstly, the procedures associated with sales and production have been simplified and harmonised in such a way that the processing of the order and the comparison of the requested profiles with our database now takes place more quickly. If a profile already exists, our customers are able to directly save costs associated with simulations and with the tools required to manufacture the cutters. Moreover, we also contact a customer if we find a profile with a marginal difference in our database that could fit and then present this to him as an option. Secondly, extensive improvements have been introduced in our IT system. In particular, they have enabled us to optimise the planning of the entire process chain from the raw part to the finished hob and to obtain a detailed overview of the production progress. In addition, all stages of production are strictly controlled and monitored. It is important to remember that a large number of operations are necessary to produce a high-quality hob cutter. For instance, 95% of the added value consists of the experience and expertise that our employees have accumulated over the years at our plant in Biel. This know-how is constantly passed on through intensive inhouse training programmes so that every new operator is able to work independently and with optimal effectiveness. Diametal has also implemented a strategy of working together with different suppliers so that, for example, the coated hob cutters can be machined within the shortest of time and with minimum delay. Thanks to all these improvements and despite constantly increasing order figures over the last few years, we have been able to drastically reduce the time we need between receiving the order and dispatching the finished tool. 4 DIAMAIL 1 16

hard materials Lagerprogramm Abwälzfräser Stock program hob milling tools

material MG10 Beschichtung / Coating TiCN Spanwinkel / Cutting angle 0

20 Ø 24 x 10/7 x Ø 8 Z 15 381222 0.25 Ø 24 x 10/7 x Ø 8 Z 15 381224 0.

50 Ø 24 x 16/13 x Ø 8 Z 15 352662 0.60 Ø 24 x 16/13 x Ø 8 Z 15 361589 0.

80 Ø 24 x 16/13 x Ø 8 Z 15 381245 0.90 Ø 24 x 16/13 x Ø 8 Z 12 358538 1.

und Zwischenverkauf vorbehalten Modifications and sales in the meantime

com DIAMETAL AG/SA Solothurnstrasse 136 2500 CH-Biel/Bienne 6 Tel +41 (0)32

5 hard materials Lagerprogramm Abwälzfräser Stock program hob milling tools Profil / Profile DIN 867 Qualität / Quality AA Schneidstoff / Cutting material MG10 Beschichtung / Coating TiCN Spanwinkel / Cutting angle 0 Artikel Article m Dimensionen Dimensions Ø 24 x 10/7 x Ø 8 Z Ø 24 x 10/7 x Ø 8 Z Ø 24 x 12/9 x Ø 8 Z Ø 24 x 16/13 x Ø 8 Z Ø 24 x 16/13 x Ø 8 Z Ø 24 x 16/13 x Ø 8 Z Ø 24 x 16/13 x Ø 8 Z Ø 24 x 16/13 x Ø 8 Z Ø 24 x 16/13 x Ø 8 Z Ø 24 x 16/13 x Ø 8 Z Ø 24 x 16/13 x Ø 8 Z 12 Preis auf Anfrage Prices on request Änderungen und Zwischenverkauf vorbehalten Modifications and sales in the meantime reserved DIAMETAL AG/SA Solothurnstrasse CH-Biel/Bienne 6 Tel +41 (0) Fax +41 (0) info@diametal.ch From our stock programme: Hob cutter with involute profile according to DIN 867 in various modules and dimensions. DIAMETAL 5

6 hard materials Virtual samples Virtual sample parts are a new and modern work tool that shows the geometry of a pinion or gear achieved under perfect working conditions. Diametal has benefited for over half a century from its experience in the manufacture of high-precision hobs made of carbide used for the gearing of transmission components. Based on the powerful CAO software, the development engineers and designers in our technical department have been developing and improving the mathematical tools and simulation models necessary for the calculation and definition of the hob cutter profiles over several decades. Regardless of the type (hobs with cycloidal or involute profile, index cutters, cutters for frontal milling), all cutters are systematically subjected to a simulation during their design stage so that a profile can be defined that makes it possible to attain the desired results when hobbing the part. Every now and then, certain gear forms requested by our customers cannot be milled without showing some differences in the profile. This typically occurs when a part with a cycloidal gearing and a small number of teeth is intermeshed, such as a pinion NIHS of the module 0.12 with 9 teeth. A slight difference between the theoretical profile and the gearing appears at the tooth root. In the case of a gear wheel with a large number of teeth, for example NIHS of the module 0.12 with 71 teeth, this difference appears at the top of the tooth. For this reason, Diametal decided to develop "virtual sample parts" and offer them to its customers in.dfx file format. This control measure, which corresponds 100% to the real results of the gearing, can be implemented directly by the machine setter or the quality control personnel. It is also very useful for the developers of clockwork mechanisms, who can use it as a comparison tool or directly integrate it into the configuration. The virtual sample parts have been particularly conceived for the hobbing of the following tooth forms: cycloids involutes We offer: 2D representations of the virtual sample as.dxf file a copy of the virtual sample in the desired scale These virtual sample parts depict the profile to be milled by the gear cutters. In order to simulate the gearing on a machine more accurately, it is essential to take possible deviations between theory and practice into account. With this idea in mind, Diametal has developed its virtual "practical" sample parts. This complements the existing concept of virtual sample parts and additionally enables tolerances in the dimensions and geometry of the hobs to be taken into account, such as concentricity, vibration or conicity. These differences can be attributed to factors like tool production, the tool holder or the specific adjustment of the machine. When the geometrical tolerances also lie in the range of several micrometers, their cumulative effect can result in not insignificant deformations for a part of the profile in this kind of cutting tool. This simulation tool is therefore very interesting and useful as an instrument to discover, explain and resolve errors during hobbing operations. It is also a valuable aid for our customers, who are then able to easily determine the cause of any error in the milled profiles. 6 DIAMAIL 1 16

hard materials Turning and milling rings for machining rubber rollers In many areas of today's printing and textile industry, a wide variety of rollers are used with a steel core and an overlying

The surface qualities and running accuracy (concentricity) that are required here lie in the range of a few hundredths of a millimetre.

7 hard materials Turning and milling rings for machining rubber rollers In many areas of today's printing and textile industry, a wide variety of rollers are used with a steel core and an overlying rubber coating. These rollers find application in various printing and deflection processes. The surface qualities and running accuracy (concentricity) that are required here lie in the range of a few hundredths of a millimetre. This level of precision is typically achieved through a two-stage machining process. The first step is carried out conventionally by turning or milling. Tools made of steel or HSS were used up to now for this pre-processing, with the subsequent finishing or final machining process completed usually by external cylindrical grinding. In the system we are highlighting, the turning takes place on traditional lathes. Instead of a turning tool or an indexable insert, a so-called turning or rotary ring is inserted (Figure 1). Firstly, the ring shape supports the removal of the long chips. Another advantage of this system is that after the active cutting edge becomes blunt, the turning ring in its bracket only has to be turned slightly and the next sharp edge is already sitting in the right position. In addition to the turning rings, a further tool system is implemented for the preliminary machining. A milling tool is used that has at least two carbide rings (Figure 2). In addition to the milling tool, also the rubber roller is set into rotation for the machining process. A major advantage of this carbide milling tool is a controlled and short chip. Furthermore, the milling tool produces a very low surface roughness and high cylindricity on the roller, so that the finishing grinding can be done in a significantly shorter time. Diametal manufactures these turning and milling rings from carbide grades that have been specifically adapted to the two aforementioned applications in their range of properties. These special micro-grain varieties enable the required maximum sharp-ness of the cutting edges to be attained in the manufacturing process with minimal chipping at the same time. By means of these two factors, it has been possible not only to significantly reduce the grinding allowance which pays off directly in a shortened grinding time but also to make the machining process more robust. More robust means in concrete terms that no sudden tool failure takes place anymore caused by spallings on the cutting edge. Various service life tests at our customers have shown that the carbide tools from Diametal can have a tool life that is 20 times higher than conventional HSS tools. We would be happy to show you how your particular applications can also be equipped with this optimal carbide quality and how the lifetime of your tools can be significantly increased as a result. Figure 1 Figure 2 DIAMETAL 7

By now more than three generations maintain the transfer of our Knowhow. We continue our innovations our 150 employees are eager to provide you every day with the best tools available on the market.

8 flash 80 years Diametal Eighty years in business and an 80-year partnership with Diametal. trade shows 2016 Positioned as a provider of customized, comprehensive solutions, the Diametal Group now stands among the leaders in its market. By now more than three generations maintain the transfer of our Knowhow. We continue our innovations our 150 employees are eager to provide you every day with the best tools available on the market. Continuity and reliability, partnership and performance, quality and creativity - are the values Diametal stands for today and tomorrow. SIMODEC La Roche-sur-Foron, France Hall D, stand P60 GRINDTEC Augsburg, Germany Hall 1, stand 1049 SIAMS Moutier, Switzerland Hall 1.2, stand C-14/E-11 imprint DIAMAIL is a publication from DIAMETAL Ltd., DIAMETAL France SA, DIAMETAL Italia S.R.L. and DIAMETAL Precision Tooling (Nanjing) Ltd. DIAMAIL appears two times a year in the following languages: German 900 copies French 700 copies English 400 copies Editors Tooling, Carbides & Ceramics: Michael Zuber, michael.zuber@diametal.ch Abrasives: Dany Warter, dany.warter@diametal.ch Editorial, International: Dr.-Ing. Michael Op de Hipt michael.opdehipt@diametal.ch Please mail any requests for additional copies or issues, any questions you may have, and any notification of changes of address to: diamail@diametal.ch DIAMETAL AG Solothurnstrasse 136 CH-2504 Biel/Bienne Tel Fax info@diametal.ch Printed on environmentally friendly paper from controlled forest cultivation. AMB Stuttgart, Germany DIAMAIL 1 16

ROLLER BURNISHING OF RADIUSES ON END FACES

1 09 Newsletter from DIAMETAL AG www.diametal.com 1/13 ROLLER BURNISHING OF RADIUSES ON END FACES In the automatic turning of watch parts, a cut-off burr often occurs. This formation happens when the workpiece