1. technology and computing

Customer magazine
No. 30
September
2007
FACTS
for coating technology
How to construct
a high-performance coating
on my tool?
Page 14
WEMA GmbH:
Increasing
cutting
Photo: Airbus S.A.S.
Airbus:
Taking
off
Pages 8-9
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Photo: WEMA GmbH
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Pages 6-7
Increasing performance
is not rocket science
In this edition
n Editorial
2
n “Thick” PVD-coatings
Coating thicknesses up to 12 µm
lead to longer tool life
3
n In-house coating with small capacities
The CC800®/9 JET brings PVD-technology
to every company economically
4
n With smooth coatings
drilling becomes easier
Longer machining of high-tempered steels
5
n High-quality tools from Bavaria
Solutions adapted to all tasks in machining
6-7
n That’s how the super bird takes off
Diamond-coated tools
optimize the production of the Airbus A380
8-9
n For special applications –
the adapted milling tools
Smooth coatings and high reproducibility
without chip congestion but with long tool lives
10-11
n Qualified manpower recruited
Twelve young adults are trained in Würselen
12
n Who said fishing is relaxing?
13
CemeCon-team successful in „The Great Fish Race“
n Imprint
14
n Four steps to the optimum coating
CemeCon presents its new internet site and
offers the easy way to high-performance coatings
14-15
n Powder metallurgy in focus
The experts of the branch meet
at the Hagener Symposium
15
n Product surfaces with an added value
Whether colored or wear resistant:
coatings refine jewelry and more
16
Dr.-Ing. Toni Leyendecker,
CEO CemeCon AG
„How do I design a high-performance coating for my
tool?“ We intend to look at this question in detail on
our internet site as well as at this year’s EMO in Hannover. For almost all modern precision tools are now
coated with extremely high-performance coatings.
Material, grinding technology, geometry and coating
are carefully coordinated with one another to achieve
the extremely high performance required by the user.
When designing a tool, tool designers know every
detail of the application, basic materials, grinding techniques, geometries and microgeometries and combine this knowledge with their expertise. However, it
is usually only major manufacturers that approach the
layout and design of the coating systematically.
Yet a coating is not rocket science – it was viewed as
such only in the early stages. However, a great deal of
time and consideration goes into creating the optimum specifications. This is because even the most
painstakingly planned tool will fail to deliver if the
designer does take pretreatment, coating material,
coating thickness and tolerances as well as color and
post treatment into account.
But how do I do that? This is a question we aim to
answer in our article on page 14 by explaining to
you the system involved in structuring and designing a high-performance coating. From September
14, you will also find this information by clicking
on our new internet site at the familiar address
www.cemecon.de. Even better, you can visit us at
the EMO, Booth B15, Hall 4.
I know that this is not the usual way of looking at
things. And that is precisely why my colleagues and
I are looking forward to some very interesting talks
with you.
Have fun reading the FACTS!
Dr.-Ing. Toni Leyendecker
2
3
Numerous benefits with the PVD method
“Thick” coatings
on cutting inserts
In order to be able to react quickly to new machining requirements and not be left behind, it is essential to recognize trends at an early stage. This also applies to the coating
industry. To achieve this, it is essential to cooperate closely
with tool manufacturers and users.
It is almost ten years since the first attempt to create PVD coatings with thicker coatings. They were used particularly
successfully on indexable inserts. The
“thick” PVD coatings from CemeCon
are coating specifications, where customers adapt coating materials such as
ALOX SN² and ALOX SN² gold to their
particular insert types and/or requirements, and successfully use them.
Just how thick is “thick”?
What does a coating specialist consider
to be a “thick” coating? After all, we’re
only talking about a few thousandths of a
millimeter. Most coatings with high thicknesses are nowadays produced using
the CVD method. The average coating
thicknesses are between 10 and 12 µm.
The coating compositions are primarily
TiN, TiCN and aluminum oxide in combination with one another. However, a
significantly wider range of materials is
now being demanded. Tool manufacturers want the option of combining
elements such as aluminum, chrome
and silicon in order to adapt the properties of the coating materials even more
precisely, thus equipping themselves in
the best possible way for new challenges
and materials. At present, the only way
to achieve this goal is through using PVD
technology. This enables the user to benefit from additional advantages such as
ultra-smooth coating surfaces and low
process temperatures.
Accordingly, oxidic coatings are no longer beyond the limits of PVD technol-
the machining process such as high
temperature. Secondly, by doubling the
coating thickness, the user gains in excess 100% tool life in some applications.
Both already the existing coatings as well
as future developments are suitable for
turning and rough milling applications in all
common steels and grey cast irons. n
ogy. Using elements such as aluminum,
chrome, zircon and others, innovative
coating materials are set to open up
completely new possibilities in the coming years. These coating materials can be
produced in combination with supernitrides, for example, in PVD-typical 3 µm
coatings as well as 8 µm and even higher
coating thicknesses – depending on the
conditions of the cutting edge and the
application.
Longer tool life
with thick coatings
The advantages of thicker coatings are
clear: on the one hand, the substrate is
protected against effects resulting from
Coatings up to 12 µm are already
possible with PVD technology.
A technology for (almost)
every purpose
In the past, manufacturers of indexable inserts in particular had to come
to terms with various technologies in
order to cater for all the requirements.
With the new PVD developments it will
soon be possible to meet a much wider
range of requirements using a single
technology. From coatings for milling
to burring and turning – in future it
will be possible to process all this and
more using a single system. Because,
in addition to modern high-tech nano
coatings, PVD technology also allows
the deposition of oxidic coatings, the
coating of non-conductive cutting ma-
terials and the creation of greater coating thicknesses in combination with the
advantages of PVD sputter technology.
In addition, the PVD method is environmentally friendly and does not result in
any toxic waste products!
Your contact at CemeCon
Inka Harrand
Product Manager
Cutting Inserts
Phone:
+49 (0) 24 05 / 44 70 105
[email protected]
In-house coatings even with small capacities
PVD coating technology for the price
of high-quality grinding technology
Working together with a tool coating company is one way
of gaining access to state-of-the-art coating solutions. An
alternative is to integrate coating technology directly into
in-house production. There are fewer obstacles than commonly perceived. Compact dimensions for coating systems
requiring only a small amount of space which are easy to
operate thanks to fully automatic process control make it
easier to take the first steps and enable tool manufacturers
to react more flexibly to customer requirements.
The advantages to tool manufacturers of
integrating high-quality PVD technology
into in-house production are obvious:
the reaction time to customer wishes
is substantially reduced, the logistics are
noticeably reduced and no transport
costs between in-house production and
the tool coating company.
Small, but
what a performance
What happens if only smaller coating volumes are required? Does it make sense
economically to use an in-house PVD system? The CC800®/9 JET makes it easier
for small and medium-sized companies
to take the first steps towards in-house
coating with tried-and-tested technol-
ogy. Despite its compact design, the
“little one” is capable of precisely the
same performance as its big “brothers
and sisters”. The CC800®/9 JET supplies exactly the same coatings, which
tool manufacturers and recoaters can
design for their applications using the
same broad range of various coating
materials of the Würselen-based systems
engineers.
The high-precision coatings created by
PVD sputter technology are distinguished
by extreme wear protection, excellent
oxidation resistance as well as hardness
and hot hardness. They also create extremely smooth surfaces, no cutting edge
roundings, with outstanding adhesion
qualities. In this way, tool manufacturers
can produce hard and
super hard coatings
with the CC800 ® /9
JET successfully and
economically within
their own companies.
Excellent
service
It is not especially
difficult to integrate
production of this
Taking the first
steps towards inhouse coating:
CC800®/9 JET.
4
kind into one’s own company. For this
purpose, CemeCon has experienced
employees who assist tool manufacturers at all stages including first draft,
installation, production start-up and beyond. Moreover, training is provided for
the in-house personnel to ensure safe
operation of the technology. In this way,
the Würselen-based company passes on
its many years of experience in systems
engineering and coating services to the
user, experience that was gained in its
own coating center. This coating center
provides the best opportunities for this.
It is, after all, one of the world’s largest.
In addition, CemeCon offers a guaranteed long-term spare part and delivery
service for consumables.
Should the coating volume increase, the
coating system can be expanded accordingly, since all CC800®/9 systems are
based on the same concept and identical process technology. As a result, tool
manufacturers remain flexible even if
batches increase in size and, thanks to
the simple operation of the systems,
are able to drastically
shorten the time
they need to
react to market requirements. n
Your contact at CemeCon
Dr. Peter Ballhause
Product Manager
Technology Transfer
Phone:
+49 (0) 24 05 / 44 70 110
[email protected]
5
JEL: Drilling in hard materials
Sharp increase
in tool lives
Innovative technologies and high-performance precision tools are in great
demand not only in the automotive
industry. JEL Precision Tools GmbH &
Co. KG is finding increasing numbers
of solutions for special applications in a number of markets. For example, a famous car
manufacturer has contacted the tool experts.
Longer tool lives when drilling in highstrength steels with an Rm tensile strength
of 800 to 1,200 N/mm2 and steels with
hardnesses of up to 58 HRC were the
goal that JEL set itself in accordance with
customer wishes. The varioius solid carbide step drills and countersinks for the
automotive industry which are used in
these application are sometimes used
with minimal lubrication. In order to
adapt the precision tools to the requirements, the experts based in Swabia designed a tool solution with coating materials from CemeCon that was customized
to this special application and which not
only creates particularly smooth surfaces
but also increases tool life by 35% from
2,000 drillings to 2,700 (cutting parameters vc=110 m/min; fp=0.24 mm/U).
JEL also sought an optimum solution
with CemeCon for the regrinding process including recoating. The Stuttgartbased tool manufacturer combined the
individual work steps in such a way that
the same performance is achieved after
regrinding and recoating as with a new
tool. n
Easier drilling with smooth coating
Of particular importance when drilling is the smooth removal of the chips from the
drilled hole as the chips otherwise block the drilled hole and the tool jams. This
applies even more with materials that tend to form long chips when being cut.
An extremely smooth drill surface, especially in the flute, ensures that the chips
are removed and creates high surface qualities thanks to the low friction of the Tland. A coating should not only be
smooth but also match the contour.
This is made possible by means of
a coating specially designed by JEL.
The company uses this successfully
on carbide drills with margins.
Photos: JEL
At JEL, modern systems technology and expertise ensure
tools with optimum performance.
JEL Precision Tools
GmbH & Co. KG
JEL Precision Tools GmbH & Co.
KG, a company of the Komet Group,
was founded in 1931 in Stuttgart and
traditionally produces threaded tools.
In recent years, the Swabian company
increasingly specialized in solid carbide drilling tools as well as all kinds of
carbide and PCD special tools. Today,
JEL has 75 employees.
JEL Precision Tools
GmbH & Co. KG
Ruppmannstraße 32
70565 Stuttgart
Germany
Tel. +49 (0) 711 / 78891-0
Fax +49 (0) 711 / 78891-11
E-Mail: [email protected]
Internet: www.jel.de
Your contact at CemeCon
Marc Semder
Sales Manager
Phone:
+49 (0) 171 / 9700 736
[email protected]
WEMA: High-quality Bavarian tools
Longer tool life –
faster cutting
Whether for mechanical engineering or the automotive industry, for basic tools or a special solution – WEMA GmbH,
based in Pfaffenhofen, offers quality and technology of the
highest degree. Thanks to a well-equipped machine park,
the company is able to produce tools for milling, drilling and
reaming at short notice. This includes not only new tools
but also a comprehensive regrinding service.
fit chuck and a coating specification based
on an extremely tough coating material.
The tools work with a cutting speed of
230 m/min and a feed of 0.05 mm per
tooth. Removal of material residues on
flat contours as well as long cantilevers
show that the tools have a high running
smoothness and good surface qualities.
Moreover, WEMA increased tool life
three to fourfold. The full-radius milling
During the product development stage,
WEMA, the development and marketing
partner, meta-cut, and CemeCon work
closely together to ensure that the coatings used are perfectly customized to
the applications. This tried-and-tested
hand-in-hand procedure allows WEMA
to adjust the tools designed by meta-cut
and coated with CemeCon technology
to the customer requirements at short
notice:
The solution for every
machining problem
For example, KBW GmbH was looking
for an optimum solution for the production of body prototypes (using the ST52
material). WEMA provided it: a Q-Cut
carbide full-radius milling tool for highperformance machining with a CAD-optimized cutting edge, tension in the shrink-
Power packages in a row: Coated WEMA milling tools stand out thanks to excellent cutting speeds and tool lives.
Sale via the world wide web
WEMA cutting
tools achieve
maximum performance in
numerous
materials.
6
Based in Pfaffenhofen, meta-cut GmbH sells carbide machining tools
from WEMA via the internet. The company places particular value
on providing products that are made in Germany and on ensuring
that tools always conform to the highest technological standards.
The symbiosis of hard metal quality, cutting geometry and coating ensure optimum
performance in various applications.
You will find further information at www.meta-cut.com
7
tools also deal excellently with pocket
milling and aluminum processing.
Process safety
in GFP and CFP
Process safety was the concern of
Thoun carbon fiber design GmbH when
processing special products using GFP
and CFP for industrial systems manufacturing and carbon-fiber products for
the sports industry. WEMA supplied a
special solution that was perfectly tailored to these applications: with the
coated single-tooth milling tools in
various diameters, which have a similar geometry to that of A-Cut carbide
aluminum milling tools, the tool life was
increased thanks to excellent c h i p
flow and the tendency
towards cutting edge
breakages was minimized.
During processing of the
very abrasive materials,
the tools – coated with
a coating based on the
coating material CC
plus D – also achieved
a 15% increase in cutn
ting speed.
WEMA GmbH produces milling, drilling and reaming
tools for mechanical and mould engineering as well as
for the automotive industry. The Pfaffenhofen-based
company works closely with dealers and distributers
and offers both new products and a regrinding service.
WEMA GmbH
Fräs-, Bohr-, Reibwerkzeuge
Fertigung und Instandsetzung
Raiffeisenstraße 9
85276 Pfaffenhofen an der Ilm
Germany
Tel.: +49 (0) 8441 / 85 916 0
Fax: +49 (0) 8441 / 85 916 20
E-Mail: [email protected]
Internet: www.wema-online.de
WEMA managing director
Max Prem.
Catalog tool
or special tool:
WEMA products
meet the highest
requirements.
Your contact at CemeCon
Frank Schönberner
Sales Manager
Phone:
+49 (0) 170 / 6310 718
[email protected]
The WEMA team in Pfaffenhofen is constantly working on adapting high-quality
tools precisely to the applications in question. Photos: WEMA GmbH
Airbus Deutschland GmbH:
Take-off with lightweight
Substrate, geometry, coating –
the fantastic trio
Photos: Airbus S.A.S.
From summer 2009, the new super airliner – the Airbus A380 – will fly 555 passengers to
their holiday or business destinations with previously unheard of comfort and economy.
The super bird is produced using hi-tech materials and designed in line with state-of-theart knowledge to enable it to withstand the enormous stresses connected with take-off,
landing and flight. Production is also state-of-the-art: thanks to optimized tools, the Airbus
workshops have increased the lifetime for drilling carbon-fiber reinforced plastic-metal
composites by more than 500% – with fantastically low drilling tolerances. This development is continued with the production of the CFRP airfoils for the new A400M military
transporter in Stade.
The European aircraft manufacturer,
Airbus, has been distinguished in recent
years by consistently high quality and innovative strength, thus reinforcing its position on the international market. Such
successes are based on close cooperation
between specialists: during the processing of fiber composites, Airbus in Stade
and Hamburg have made dramatic savings in terms of time and money thanks to
individual diamond-coated solid carbide
drills developed in cooperation with
several companies.
8
Economic effectiveness
through expertise
weight of the new A380 – a figure which
is currently unique.
These savings are important as good
production costs for aircraft construction are a high priority – as important
as a high level of safety and longevity as
well as reduced fuel consumption. For
this purpose, designers are turning to
hi-tech lightweight such as advanced
aluminum alloys (AlSi) and carbon-fiber
reinforced plastics (CFRP). CFRP now
constitutes some 22% of the structural
However, this material is very demanding in terms of machining, particularly
with regard to tool wear when drilling
blends of CFRP, aluminum and titanium
in the Hamburg A380 assembly plant.
In order to fulfill this machining task
with acceptable lifetimes and optimum
qualities, the most suitable tools must be
acquired: one reason for Airbus to use
the expertise of leading tool experts.
9
Specialists cooperate
for optimum results
In cooperation with the Swiss carbide
manufacturer, Extramet, the tool
manufacturer Klenk based in Balzheim,
Baden-Württemberg and the coating expert, CemeCon, Airbus have received
products customized to their special
requirements. In the joint project overseen by Hamburg Harburg Technical
University, substrate, geometry and
coating were precisely designed to the
areas of application.
Taking off with diamond
The 555 passenger capacity can only be
achieved by having two levels, which has
been achieved for the first time with this
aircraft cabin. The upper deck floor
beams are made of CFRP and must be
connected with the bearing structure,
in this case aluminum ribs.
The diamond coating used in the
machining of this material combination is in its element: using uncoated
drills, the tool life quantity was only
90 drillings. After coating with an individually adjusted variant of the coating
material CCDia®Fiberspeed, 500 holes
were achieved in the first drilling tests
– without a drill or coating failure.
Bruno Süess, Managing Director of Extramet AG in Plaffeien: “By using diamond-coated tools, we increased the
tool life by more than 500% for this application. This was based on a substantial
reduction in the drill’s circumferential
wear. Reduced replacement times and
considerable savings potential in tool
procurement costs also ensure drastically increased economic effectiveness
in the production while at the same time
guaranteeing optimum surface quality.”
Diamond masters CFRP
For the wing of the new A400M military
transporter, it is necessary to produce
rivet holes with diameters of 10 mm for
connecting the stringers and wing skin.
Stringers are longitudinal lightweight reinforcements which increase the rigidity
of large-surface components. Stringers
and wing skin are made of innovative
CFRP materials and should be drilled
together in one step of the process.
the coated drills can totally withstand
the severely abrasive wear caused by
CFRP. Moreover, diamond offers the
greatest possible resistance towards
chemical influences, thus preventing
adhesion of the workpiece material. n
Horst Klenk, Managing Director of
Klenk GmbH & Co. KG in Balzheim:
“When drilling CFRP, it is important to
avoid delaminations, i.e. separation of
the external material layers. The high
tolerance H8 class precision required
by Airbus could only be achieved economically with the diamond-coated tool.
Uncoated drills were not suited to this
material combination and the high level
of abrasive wear.”
The most competitive coating solutions
were diamond multilayers in the CCDia®
series: due to their extreme hardness
Kontakt:
Klenk GmbH & Co. KG
Mühlstraße 17
88481 Balzheim
Germany
Tel.: +49 (0)7347 950-0
Fax: +49 (0)7347 950 128
E-Mail: [email protected]
www.klenk-tools.de
Extramet AG
Hartmetallfabrik
Rüttistraße 9
1716 Plaffeien
Switzerland
Tel.: +41 26 419 91 00
Fax: +41 26 419 91 29
E-Mail: [email protected]
www.extramet.ch
mimatic Zettl: The road to optimum design
Circular milling tools
for special applications
„mimatic Zettl“ – a global synonym for quality and perfect
customer-specific solutions for CNC precision and special
tools. Since 1974, mimatic Zettl GmbH, based in Betzigau,
has been a first-class address for the automotive, mechanical engineering, aircraft manufacturing and timber
processing industry with respect to circular milling tools
for contour and thread manufacturing as well as grooving and burring tools for interior, exterior and axial
processing. Using tools specially developed for this,
the Allgau-based experts offer their customers greater
productivity.
The broader the product range, the
more successful the Betzigau-based
company is in solving tricky application
cases with specially designed tools, in addition to the tried-and-tested standard
products. No wonder the corporate philosophy is based on the synergy of highly
motivated, expert staff with an excellent
standard in the field of technology and
development. As a result, mimatic Zettl
is able to implement every special solution perfectly.
10
the South of Germany approached CemeCon in Würselen, Aachen. The coating
specialists offer a wide range of coating
materials and production methods that
enabled mimatic Zettl to design the
optimum coating specifications for their
application. In this particular case, an
extremely smooth surface and reproducibility were of utmost importance,
especially with respect to the coating
thicknesses.
The tool that was thus designed and
produced enjoyed resounding success:
dimensionally accurate free-form contours, passes and threads true to gauge
size can now be produced without chip
congestion with long tool lives, short
processing times and without expensive
special tools, particularly in the application case described. Threads in blind holes
that reach almost to the base are possible
without undercuts.
Difficult task –
smooth solution
As a globally active medium-sized production company, mimatic Zettl GmbH
manufactures driven tool units for CNC machines and processing centers. Founded in 1974, the company currently employs 140 people and has a subsidiary in
the USA in addition to its production site in Betzigau, Allgau.
This is where the wheat is separated from
the chaff. After all, every parameter must
be perfectly coordinated to match the
application. For example, when using
circular milling tools for contour and
thread production in a difficult application
case for which mimatic Zettl had to find
a solution: In addition to the tools specially developed for this case, an adapted
coating also helped to solve this particular
problem. To do so, the company based in
mimatic Zettl GmbH
Tool Systems – Präzisions- und Sonderwerkzeuge
Westendstraße 3
87488 Betzigau
Germany
Tel. +49 (0) 831 / 57 444 – 0
Fax. +49 (0) 831 / 57 444 –90
E-Mail: [email protected]
Internet: www.mimatic-zettl.de
Thoste
Tel.: +4
11
Consistent performance
for carbide inserts
This success spurred the company on
to further projects: the range offered
by the Würselen company allows mimatic Zettl to compose an individual
coating on their carbide inserts for dry
and wet processing of steel, cast and
stainless steels. The desired effect: long
tool lives and shortened processing times thanks to higher cutting speeds.
A homogeneous and reproducible
coating thickness ensures a consistent
performance. Triangular inserts, multitooth thread inserts, three-edged and
six-edged inserts with a polygonal plate
fit as well as grooving inserts are part
of the program.
perfect-fit coating necessary for the
application in question. For example,
the new generation of circular milling
tools in conjunction with carbide inserts makes it possible to integrate
security ring grooves, metric ISO internal and external threads as well as
Whitworth pipe threads into components with great precision. The polygonal connection
of cutting insert
and milling
body impro-
Since then, the close cooperation
between the specialists has continued producing new synergies leading
to innovative tool solutions as
evidenced by the new mimatic
Zettl circular milling tools with
polygonal plate fit and six cutting edges for maximum machining
volumes. On the basis of existing
requirements, mimatic Zettl is contributing its own very specific ideas for
ves the economic effectiveness of the
machining process thanks to longer
tool lives, higher machining volumes
and feeds as well as shorter processing times. n
Circular milling
inserts with six
cutting edges
from mimatic
Zettl supply
consistent
machining performances
thanks to even coating
thicknesses.
Your contact at CemeCon
Frank Schönberner
Sales Manager
Phone:
+49 (0) 170 / 6310 718
Fotos: mimatic Zettl
[email protected]
CemeCon in the world of sport:
Trainers unpacked!
That CemeCon is not just a team in the professional sense
of the word but also works together in completely different areas is proven by our representatives from CemeCon
at the annual Lousberg race, a spectacular sporting event
organized by RWTH Aachen University.
Around 2,000 runners
took to their heels
on July 11, 2007, and
navigated their way
up the Lousberg in
Aachen. CemeCon did
not let this event pass
it by. Seventeen coating
expert employees in
peak condition showed
their fighting spirit on
the 5,555 meter-long
CemeCon-sportsmen in peak condition fought for the
route. And they were
best places on the 5,555 meter long route.
not alone: Numerous
en Rübben, Mohamed Boubrik, Aydin Yildirim
49 (0) 2405 4470 113; -513; -543
From “walking-preferrer” to “speedfreak”: all types of sportsmen joined
the race.
colleagues lined the route in order to
cheer them on and shout words of encouragement.
And their efforts were not in vain: After
only 22 minutes and 14 seconds, Christoph Schiffers was the first CemeCon
representative to pass the finishing line.
Ewa Bienk was the first of the women to
finish. After 30 minutes and 23 seconds,
her colleagues were able to greet her
as she crossed the finishing line. Reason
enough to celebrate at the CemeCon
stand! n
Training in Würselen
Equipped for the future
The youth of today are the specialists of tomorrow: CemeCon adheres to this motto and offers training in various
fields. By doing so, the coating expert ensures that it will
have qualified staff in the future.
CemeCon provides training in six professions and at the moment the Würselenbased company is training twelve young
adults: Andreas Janoschka, René Unkart
and Waldemar Triller as machine/systems
operators, Nina Burhof as a technical
draughtsperson, Sebastian Jung as a mechatronist, Timo Gossen as a computer
scientist and Claus Binz and Kathrin
Knipprath in commercial professions. At
the start of August 2007, a prospective
machine and systems operator, Sven
Zielinski, an industrial sales representative, Jennifer Dahmen, and Heiko Fazlic,
who is retraining as an industrial sales
representative, and industrial mechanic,
Michael Beumers, started their training.
In order to allow trainees and apprentices
to get to know one another and to promote teamwork, the Human Resources
department organizes a trainee day every
August, this year with the focus on sport
in Kletterwald-Niederrhein. Moreover,
12
during the training period, CemeCon offers further training in „Communications
and Holding Discussions for Trainees“ and
„A Business Manual for Trainees“ as well
as other courses such as „Making Presentations in the Final Examinations“.
Gaining an insight
into all departments
Kathrin Knipprath (22), an industrial
sales representative trainee, reports on
her experience of training up to now:
“During the training as an industrial representative, I have worked in all departments of the company. To begin with, I
became familiar with Production and
the processes involved there and learned about the coating process. Then, I
went to Sales Support. I was involved in
all areas of activity and worked independently following appropriate instruction.
Purchasing was the next department on
the list. My activities there began in the
A team with
future (from
the left): Nina
Burhof, trainer
Claus Binz, Kathrin Knipprath,
Michael Schulteis, René Unkart, Waldemar
Triller, Timo Gossen, Hayrettin
Kursat and Andreas Janoschka.
warehouse where I became familiar with
the products required for the process.
After a short time, I was working independently and often had contact with
the creditors. I am currently working
in Information Technology where I am
learning about the company network
structure and picking up the basics of
data processing. It is particularly good
that as a trainee I am integrated into the
team and, wherever possible, am able
to carry out the same activities. Another
good thing is that CemeCon offers apprentices the opportunity to take part in
vocational seminars.”
From training to
a permanent job
Hayrettin Kursat (machine and systems
operator) and Michael Schulteis (industrial sales representative) prove that the
end of training is not the end of the road
at Würselen. After passing their final examinations, they were given permanent
jobs. Michael Schulteis took up his job
in the Service, Purchasing & Logistics
department and Hayrettin Kursat in the
Coating Service Production Diamond
department. n
13
A successful fishing expedition in „The Great Fish Race“
Fishing fresh fish ...
Fishing can help you to relax, or so they say ... That this
sport can also be wildly exciting, however, was proven by
the CemeCon English regional sales manager, Darren Cox,
and his team in the „Great Fish Race“ in Poole near the
English Channel in the South of England.
Even the most powerful of men in the
world do it. Discussing politics, they sit
there with their rod and net, waiting
for a fish to bite. However, the contemplative nature of a state visit of this
type is completely absent from a fishing
competition. Because no matter what
fish is being hunted down, every team
member must remain on the ball at all
times. After all, they have to get more
fish to bite within a specified time than
their competitors in order to claim the
coveted cup, the winner’s prize or
even just some fame and renown for
themselves.
Stiff competition
A mere two fish made all the difference in
deciding who won and who came seventh
– this is what Darren Cox found out at the
“Great Fish Race” in Poole, near his home
town in Dorset, in the South of England.
That was where, in early-June, the task
was for each team of four to get as many
fish as possible to bite within an eight-hour
time span. To this end, two teams started
by boat in order to “fish” for the first prize
of £1,200 as well as other prizes.
Darren Cox: “Even though the competition between the teams is absolutely
fierce, there is no end of fun when we’re
out there fishing.” At this time of year,
the waters around Dorset are home to
perches, mackerels, rays, codfish, gurnards, plaice, dogfish and sea eels. Each
one receives two points, whether it is
only a few centimeters or one meter
long. Points are only awarded for fish
that are actually caught. By contrast,
some smaller species only receive one
point. As soon as a team member has a
fish on his hook, the fish is identified by
both team captains and the skipper and
thrown back into the water, still alive.
This species can then be struck off the
catch list.
The right equipment
for every fish
“The unique thing about this competition is that we always have to get used
to new species of fish. To do this, we
constantly change our fishing equipment
and the baits in order to catch the fish
we’re still missing,” says Darren Cox.
Even when the competition itself is over,
The CemeCon team came seventh in the “Great Fish Race” (from left):
Terry Fuggle and Paul Hollyoake (Suisse Autoturn), Darren Cox
and Eddie Taylor (Trucut Tools).
Two fishing teams in a boat. Off the
coast of the south of England, the
CemeCon team went looking for fish
such as mackerel, cod, dogfish and
rays.
the fun continues over a luxurious meal
with refreshing drinks – providing ample
time for the participants to exchange
their fishing tales.
In 2007, a total of 38 teams on 19 charter boats took part – and all participants
were very close together in the results.
A mere nine points separated the best
eight teams from the winner, who had
36 points. With a score of 27 points,
the CemeCon team came seventh,
and the sponsor rewarded each team
member for their achievement with a
brand-new fishing rod. Darren Cox: “To
be beaten by the England International
Team, world champion in 2006, and to
come seventh in 38 teams is a wonderful
achievement for us. We are very proud
of ourselves. Maybe next year, we’ll do
even better!” n
Coating experts unveil their new look
Extensive information
about innovative technology
„Greater efficiency“ is the motto under which the online
editorial department at CemeCon is currently presenting
the company’s new internet site after a thorough preparatory phase. Not only does the website now look attractive
and modern, but users can also quickly find the information
they require about coating solutions.
Coating technology continues to be
a topic shrouded in mystery: what
kind of coating will provide me with
the most economical solution to
my machining task? What size system is the right one for my coating
volumes? What kind of preparation do my tools need in order to
achieve the quickest possible coating?
You will find answers to these and
other questions on the new CemeCon
internet sites, in which the company
provides full and clear information
about coatings and systems technology.
Imprint
Published by:
CemeCon AG
Adenauerstr. 20 A4
52146 Würselen, Germany
Tel.:+49 (0) 24 05 / 44 70 100
Fax:+49 (0) 24 05 / 44 70 199
www.cemecon.de
[email protected]
Editor:
KSKOMM • Pleurtuitstr. 8
56235 Ransbach-Baumbach, Germany
Tel.:+49 (0) 26 23 / 900 780
Fax:+49 (0) 26 23 / 900 778
www.kskomm.de • [email protected]
All rights reserved. Reprints, even extracts
only with permission of CemeCon.
14
Four steps to the goal
Achieve your own coating in four steps
– no problem thanks to the modular system at CemeCon. If you’re interested,
you can obtain even more quickly all the
information you need about the methods of designing a coating as the basis
of your own excellent coating solutions.
The user’s tool and coating requirements are defined using checklists.
After joint assessment of the test results
and comparison with the requirements
profile, the final coating specifications
are compiled and the question of
whether to use diamond or PVD in the
production of the coating is addressed.
The individual production process for every customer is saved in a bar code. That
makes the unique combination of coating
How is a modern high-performance
coating designed?
CemeCon designs and produces
individual coatings for various machining applications and tools as
commissioned by customers. The
specifications are designed 100%
in keeping with customer objectives
and adapted precisely to the tool and
the application. As a result, the user
achieves considerably higher performance than with traditional standard
coatings.
The formula for
(coating) success:
Coating = pretreatment + coating material + coating thickness +
tolerance + colour + post treatment.
CemeCon has developed a number
of modules for each of these individual components of a high-performance coating. In conjunction with
CemeCon, tool designers use these
modules to “construct” coatings that
correspond to the exact purposes of
the tool. This is not as complicated
as it sounds. On the contrary, since
this design produces extremely highperformance precision tools that can
always be (re)produced at a later stage
thanks to the systematic procedure
involved.
… the following four steps to your
own coating:
n definition of the objective
n determining of coating
specifications
n production of sample tools
and tests
n finalization of the specifications
Of course, this procedure may be executed more than once for complex
applications. The important thing is to
record all details of the elements for
constructing the coating with regard to
their effect when the product is used.
If this is the case, this procedure will
result in extremely efficient user-specific high-performance coatings.
15
specification for the particular application
even clearer and offers reproducibility for
many years.
System technology
and periphery
out of one hand
But the new internet sites don‘t only
offer helpful information about how to
accurately construct an individual coating, also in the field of coating systems
the visitor will find his way.
of a turn-key PVD coating
line, as well.
Also the customer services took a center stage
in the design of the internet site. Hyperlinks to
these sections deliver the
appropriate information
– so no question will be
left unanswered. n
With one click he can reach sectoral
information and can see several coating
systems from the compact CC800®/9
JET to a second hand system. Because
pre- and posttreatment play also a
important role for the success of a
coated tool, a huge product range from
adapted periphery to coating technology is presented, too. The internet site
shows the possibilities and advantages
Right from the homepage of the new
internet sites the visitors gets basic
information concerning coating
technology by CemeCon.
26th Hagener Symposium:
Professional expertise
for powder metallurgy
The Hagener Symposium is among the leading events in the
powder metallurgy industry in the German-speaking countries of Europe. For 25 years, the various topics that have
formed the focus of the symposium, the expert speakers,
the accompanying exhibition and the evening entertainment have been ensuring the success of the symposium.
The highlight of the annual symposium is
the award of the Skaupy prize to scien-
tists who have made a major contribution to powder metallurgy. Celebrating
the 25th anniversary of the symposium in
2006, Prof. Dr. Herbert Danninger from
the Vienna University of Technology was
awarded the prize by the Chairperson
of the Committee, Prof. Dr.-Ing. Bernd
Kieback from TU Dresden, and the head
of the working group for hard metal in the
powder metallurgy industrial association
in Hagen, Hans Kolaska.
Prof. Dr.-Ing. Bernd Kieback and Hans
Kolaska presenting Prof. Dr. Herbert Danninger from the Vienna Institute of Technology with the Skaupy Certificate.
On November 29 and 30, 2007, the
26th Hagener Symposium will again
be held in the city hall of Hagen. This
year’s theme is “Powder metallurgy for
high-precision components and dense
high-performance materials”. Fifteen
talks will be given by representatives
from the world of research and industry about new materials produced
using powder metallurgy and production procedures. The talks are aimed
at designers, production engineers,
plant engineers and materials scientists. However, the various materials
such as aluminum, hard metal and ceramics as well as biomedical materials
will also feature in the talks. CemeCon
frequently contributes to the event in
Hagen in the form of talks and exhibitions as well. For example, Dr. Oliver
Lemmer, COO at CemeCon AG, spoke
about new trends in the development
of hard material coatings at last year’s
event. The program and the registration documents for the 26th Hagener
Symposium (November 29/30, 2007)
can be found in the attachment.
Ara-Coatings:
Impressive
impressive products!
KBS: Koreanischer
Marktconcepts,
in guten Händen
Clocks tick in
glowing colors here
Winning the Central Franconia Founder Prize and the 2007
Bavarian Founder Prize in the „Concept“ category speaks
for itself: Ara-Coatings GmbH & Co. KG is one of the upand-coming companies in Germany – and it uses technology
from CemeCon.
On the winner’s podium thanks to
coating solutions: Dr. Ralph Domnick
(bottom right) and his team receiving
the Bavarian Founder Prize.
With its globally unique range of services,
Ara-Coatings impressed the judges and
secured itself the top-most position:
The company develops, produces and
markets surface refinements which are
manufactured using nanotechnology.
This procedure allows product surfaces
to be treated so that their properties
such as scratch resistance, temperature
resistance and wear-and-tear characteristics can be improved while still allowing the product to blaze forth in the
most dazzling of colors.
Ara-Coatings GmbH & Co. KG was
founded in October 2006 and has
specialized in the development and
production of decorative and functional coatings. Using these coatings,
the company refines jewelry, clocks, n
cutlery, cosmetic utensils, writing
implements, cell phones and ceramic
products.
The success of the young company
reflects the very good cooperation
between Ara-Coatings and CemeCon.
The system technology from Würselen
was adjusted to meet the requirements
of the decorative, functional coatings
from Central Franconia. The two companies worked hand in hand from the
development phase onwards, thereby
creating the special solution for the
colorful layers.
Ara-Coatings GmbH & Co. KG
Managing Director:
Dr. Ralph Domnick
Gundstr. 13
91056 Erlangen
Germany
Tel.: +49 (0) 9131 / 932150
Fax: +49 (0) 9131 / 932155
Mobil: +49 (0) 176 / 20388051
E-Mail: [email protected]
Internet: www.ara-coatings.de
Events Calendar
CemeCon will be represented at the following trade
fairs and events this year:
EMO in Hannover: 17. to 22. September 2007.
Hall 4, Booth B15.
AEPSE in Nagasaki (Japan): 24. to 28. September
Medica ComPaMED in Düsseldorf: 14. to 16. November
Hagener Symposium in Hagen: 29. to 30. November
EuroMold in Frankfurt: 5. to 8. December
16