Schleifen Sie gut!

“We tried to split the micrometer.”

Horst Bader has the story of Haas Grinding Machines.

Visit us at EMO in Hanover: 18 - 23 September 2017 · Hall 6 – Stand K45

SEPTEMBER 2017

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GSF SEPTEMBER 2017

SEPTEMBER 2017VOLUME 15 | No.4 ISSN 1740 - 1100

EMO 2017 PREVIEW 4SPECIAL REPORT - AZ SPA 28Production Grinding 30

Advanced Engineering 2017 42

Grinding Wheels & Discs 44

PREVIEW - DEBURRING EXPO 50FEATURE - DEBURRING 58Honing 64

Polishing & Lapping 66

SPECIAL REPORT - HAAS SCHLEIFMASCHINEN 70FEATURE - TOOL & PROFILE GRINDING 74Filtration 80

PREVIEW - Parts2Clean 82Component Cleaning 86

Metal Finishing 92

At Your Service 98

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Grinding & Surface Finishing is a controlled circulation magazine, availablefree to selected personnel, at the discretion of the publisher.This material is copyright. No part of this publication may be reproduced withoutexpress written permission. Please contact the publisher.

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• Medical Report• Blast Cleaning

• Component Cleaning• Dust & Fume Extraction• Honing & Bore Finishing

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COVER STORY 3

“Trade fairs are veryimportant for Haas”Thirty years ago in 1987, German grinding machine builderHaas exhibited for the first time at EMO in Hanover, an eventwhich today is the no 1 trade fair for the metal workingindustry.

“I have always believed that trade fairs are a very importantinstrument for spreading the word about our products. Personalcontact with our users has always been a top priority for me”, saidHorst Bader, former owner of Haas who passed away much tooearly in 2015.

An in-depth interview with the passionate engineer, whosuccessfully led the company for 18 years, tells the story of HaasGrinding Machines and can be found as part of the special reporton pages 70-72 of this issue.

Horst Bader in his time had the same clear goal as had AdelbertHaas, the company founder, i.e. to build the best universal grindingmachines for customers worldwide. Haas remains true to this goaltoday, with the perseverance and love of technology that people insouthern Germany clearly have in their DNA. The results of thisattitude are Multigrind® grinding machines, grinding software andgrinding processes that don’t follow the latest technological trends,but instigate them instead.

Today, Haas CNC grinding machines can be found in state-of-the-art manufacturing facilities all over the world. The MultigrindCB, Multigrind CA and Multigrind CU high-tech CNC grinders areused in almost every industry that processes metal. These includemedical engineering, precision tool manufacturing, gearmanufacturing, the aerospace industry and the energy industry.

Multigrind grinding machines are manufactured in Germany byHaas Schleifmaschinen GmbH and are being sold and serviced inthe UK and Ireland by Geo Kingsbury (Portsmouth, UK) from thebeginning of 2017.

Haas will exhibit at EMO in Hannover in Hall 6, Stand K45

Haas Schleifmaschinen GmbHUK Agent: Geo Kingsbury LtdTel: 023 9258 0371Email: sales@geokingsbury.comwww.geokingsbury.com

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Haas Schleifmaschinen GmbH was foundedby Adelbert Haas in Trossingen on the edgeof the Black Forest in 1934.

Since then, the Schwabian grindingspecialist has developed and built machinesfor a wide variety of industries andcustomers across the globe. Wheneversomeone receives a prosthetic knee, forexample, there’s a 75 percent chance that itwas manufactured on a Haas Multigrind®machine. Also, thanks to Multigrindmachines and Multigrind Horizon grindingsoftware, Haas has an excellent reputation inthe aerospace industry and withmanufacturers of precision tools.

There is sometimes confusion over thename Haas, as there is another leadingcompany in the marketplace – HaasAutomation. However, the two companiesare oceans apart not just geographically butalso with their quite different technology.

Haas Automation, headquartered inOxnard, California, was founded in 1983 byGene Haas and is a major manufacturer oflathes and machining centres, while HaasSchleifmaschinen is a specialist in grindingtechnology.

Unlike turning and milling, where thereare defined cutting edges but also issueswith swarf, grinding involves machining tomicrometric tolerances and where neitherthe shape nor the number of cutting edgesare known.

Under the guidance of Horst Bader, apassionate qualified engineer and machinebuilder, the company designed and builtnearly 500 grinding machines in Trossingenbetween 1982 and 2000, including the first2-axis tool grinding machine in 1984, thefirst CNC HB 3045-5 with five axes in 1989and the highly successful Multigrind HTrange in 1998.

A true pioneer Before Horst Bader’s untimely death in2015, he was interviewed for the company’sSchleifblog. He was firstly asked about thecompany founder Adelbert Haas:

“Adelbert Haas opened his workshop onNeckarstrasse in Schwenningen, SouthGermany in 1934 when he was 34 years old,under the name Haas & Jauch Werkzeugbauand became the sole owner in 1937 or 1938.He was a mechanic with electrical trainingand always demanded high technicalstandards. In the beginning, he even builtmotors himself for his machinery because hewas dissatisfied with the electric motorsavailable in the market.

“If memory serves, Adelbert Haaspresented his first grinding machine at theLeipzig Trade Fair in 1938. Haasmanufactured two grinding machine modelsuntil the end of World War II, the HS 1 toolgrinder and the FL 325 surface grindingmachine. The basic design was the same,but the tool grinder features a swivelling

head and the surface grinder a rigid spindlehead.

“I believe that the first company Haassupplied was Nagele Feinwerkbau inStuttgart both before and during theWar.The customer built machinery andsystems for the manufacturer of zippers forclothing. The tools used in the folding,compressing and crimping machines had tobe reground on a regular basis and this wasdone on a Haas machine.

“Haas employed about 120 people until1945, when the company headquarterswere completely destroyed by an aerialbomb with none of the systems or machinesleft standing. Adelbert Haas beganrebuilding the company near the old site,but despite any support or machines hemanaged to manufacture a surface grindingmachine, which was supplied to anotherzipper manufacturer, this time in Sweden.Up to the late 1950s, Haas manufacturedjust one tool grinding machine, jokinglyreferred to internally asBlechschusselmaschine (metal bowlmachine). High-quality materials like steel,iron and the like were very hard to come byafter the War. The machine was designed tocapture grinding dust and emulsion. Awooden frame below the metal bowl servedas a machine stand.

“In the late 40s, the grinding spindle wasrelatively small, with a diameter of just 60mm, while the taper for the wheel flangeshad a diameter of 15 mm. In the late

A passion for grinding

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50s/early 60s, a very sturdy machine standwas introduced and the diameter of thegrinding spindle increased to 90 mm. TheHS 1 was a highly stable, accurate andreliable machine manufactured at Haas foraround 40 years.

“Adelbert Haas was always improving theHS 1 and expanding the accessories. Forinstance, he replaced the ball screw guidewith the ball hanger rod guide in the late70s, again making the table guide muchsturdier. This made the grinding processmore accurate. Haas won over manyrenowned customers with its high-precisiontable guide and always very good grindingspindles. There were more than 20 grindingmachines in use at both Märklin Modelrailroad in Göppingen and Groz-Beckert inAlbstadt.

New ownership brings huge advances“I joined Haas in 1982. Before that, I workedin the field of machining engineering as aqualified engineer and already had businessdealings with Haas. When I took overAdelbert Haas’s company, he was 82 yearsold and still had six employees. He came inevery day and really helped me settle in. Inmy first year, we manufactured around 40machines, split equally between surfacegrinding machines and tool grindingmachines.

“Development of the first CNC grindingmachine began two or three years after Itook over the company. It was clear to methat our HS 1 tool grinding machine was stillgood, but it was no longer up-to-datetechnically speaking. The Haas company

wouldn’t have survived much longer withoutthe CNC machine, so we introduced the firsttwo-axis CNC machine with step motor andcontroller at EMO in Hannover in 1987.

“We launched the first 5-axis machinewith CNC controller in 1989, after havingmanufactured 3- and 4-axis machines basedon the HS 1 for some time. Before that therewas the HB 1035 with two axes, the HB 2035with four axes and Siemens controller andfinally the HB 3045 with up to six axes. TheMultigrind® HT was developed on thisbasis, with more than 400 machines sold.

“We began developing software inaround 1990. Back then, we still developedthe programs for the grinding process onthe computer and then entered them intothe Siemens controller. Those were the firststeps towards software-controlledfull-sequence machining of tools on ourgrinding machines.

“Around this time, we carried out ademanding, large-scale project forHeidelberger Druckmaschinen. Two HB3045 grinding machines with Siemenscontroller allowed users to grind tools fromstart to finish. Heidelberger was a greatreference for us, which ultimately helped usto get our foot in the door withDaimler-Benz, MAN, and BASS. Incidentally,BASS is still a Haas customer to this day, andan absolute specialist in threading tools.

“Our Multigrind® CB, CA, and CUgrinding machines can be used toeconomically grind a wide variety ofworkpieces and parts. I have alwaysbelieved that trade fairs are a very importantinstrument for spreading the word aboutour products. Personal contact with ourusers has always been a top priority for me.EMO in Hannover and AMB in Stuttgartwere the most important trade fairs at thebeginning and gave us the opportunity tomeet with customers and interested parties.We always received new ideas fordevelopment there. We first contactedcustomers and representatives from abroadat EMO.

“The first GrindTec was a very importantstep for us. There we had the opportunity tomeet with people who were reallyinterested in grinding technology. GrindTecin Augsburg was, from the first day, aspecialist trade fair in the best sense of theword. In addition to trade fairs, it was alsothe recommendations of satisfied users thatallowed us to advance. Word has spreadabout the quality of the Haas grindingmachines Made in Germany.

“With the launch of the CNC machines,we began purchasing controllers, electroniccomponents, and guides, but only fromsuppliers that lived up to our own qualitystandards. The vertical range of

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manufacture has therefore remained high atHaas.

“We used the single-grain diamond todress grinding wheels of a certain shape.The single-grain diamond was mounted in adevice and used to expose new grains in thegrinding wheel, thus resharpening thegrains and reinforcing the grinding wheel. Ialways had the single-grain diamond eitherin my pocket or in my drawer. Today at Haaswe dress with dressing units inside themachine.”

Cross dressing unit in a Haas Multigrind CU“Profiling is carried out with a paralleldresser in this machine or by using a crossdressing procedure. Here, the dresser wheelis positioned at an angle of 90 degrees tothe grinding wheel. For the

pressure-sensitive tapered wheels used togrind smaller radii in cutting tools, theprocess is much gentler.

“We’ve always built machines that allowyou to grind in the micrometer range. Ourcustomers demanded this level of precisionof us. In my time, we worked with extremelyaccurate Heidenhain scales in micrometerresolution. For rotary axes, we usedencoders with angular resolutions down to athousandth of a degree.

“In medical technology, when it came tothe grinding of the contours of kneeimplants, they had to work in increments of amicrometer. That resulted in 420,000individual lines of code in the grindingprogram, which was too much even for theSiemens controller, so we spoke to theSiemens experts, who then expanded thestorage capacities of the controllers for us,otherwise, you wouldn’t have been able tocarry out this complex grinding process.That was a good collaboration. As you cansee, we worked very accurately back then,too. Even if the grinding machines that leave

Haas these days are more precise due tomore accurate guiding systems and betterspindles and probing systems.

“A few of the HS 1 machines are stillprimarily used for reworking or regrindingand they virtually last forever. In my day, weusually delivered four to five HS 1 machinesa month. By 2004, Haas had manufacturedaround 2,400 mechanical tool and surfacegrinding machines based on the HS 1. Thencame the CNC grinding machines andbusiness with the HS 1 declined. Therepeatability of our new CNC grindingmachines was simply much better.”

Haas Schleifmaschinen GmbHUK Agent:Geo Kingsbury LtdTel: 023 9258 0371Email: sales@geokingsbury.comwww.geokingsbury.com

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