Grinding beyond the machine Grinding as a system: How integrated process chains secure precision

Grinding is becoming a system technology. At Grinding Hub 2026, examples from brake disc machining, in-process metrology, CBN tools and tool supply showed how closely machine, tool, measurement technology and process knowledge now have to interact to secure precision, efficiency and process reliability.

When tight tolerances, demanding surfaces and stable series production processes are required, grinding is a key technology in modern manufacturing. Increasingly, the decisive factor is no longer the individual machining step alone, but the interaction between machine, tool, process knowledge and metrology. Grinding Hub 2026 in Stuttgart showed how integrated process chains can improve precision, efficiency and process reliability in grinding.

Precision is created through interaction

This system-based approach becomes particularly clear with demanding workpieces such as brake discs. They react sensitively to mechanical and thermal loads. Excessive process forces can quickly lead to distortion and thus to deviations in lateral runout and parallelism. The aim of modern grinding processes is therefore to make material removal as gentle as possible while also ensuring reproducibility.

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One approach is the consistent consideration of the entire process chain. Coating and grinding are designed as an integrated process, while machines, grinding tools and cutting media are precisely coordinated with one another. At Nagel Technologies from Nürtingen, this covers the entire machining process. “When it comes to grinding today, it is no longer just about material removal, but about the controlled interaction of all process components,” explains Andreas Schmohl, Managing Director of Elgan Diamantwerkzeuge and Head of Business Unit Superfinishing at Nagel Technologies. “Our goal is to keep process forces as low as possible in order to avoid deformation and achieve the highest precision.”

Technically, the approach is based on double-disc face grinding, in which both sides of the brake disc are machined simultaneously. The uniform load distribution reduces local force peaks and enables stable processes over the entire service life of the self-sharpening grinding segments. Practice shows the breadth of this technology: for customers, around 40,000 coated brake discs in approximately 300 variants have already been machined in pre-series and prototype production. Both passenger car and truck brake discs can be produced on one machine — as can coated cast-iron brake discs and ceramic variants, with only the cutting medium needing to be changed.

Precision grinding

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Metrology closes the quality control loop

Metrology is also becoming increasingly important in the grinding process. It makes it possible to detect deviations at an early stage, feed process data back into the system and secure quality directly in the machine’s working area. Renishaw presented probe solutions that record the position, orientation and condition of the workpieces and thus enable geometric feedback for the quality control loop.

“Our probes record the position, orientation and condition of the workpieces. Determining the actual material allowance avoids unproductive ‘air cuts’. Final inspection can also be carried out directly in the machine’s working area,” reports Dr Jan Linnenbürger, Business Development Manager EMEA at Renishaw, whose German site is based in Pliezhausen. “This enables users to achieve a high level of process capability, even with fluctuating process parameters. By integrating geometric measurement into the grinding machine, process reliability and efficiency are significantly increased.”

A particular feature of Renishaw technology is its accuracy in 3D measurement. “Renishaw is known for achieving repeatability of less than 0.25 micrometres,” Linnenbürger emphasises. For the demanding requirements in grinding machines, the company uses robust and compact probes as well as motorised measuring arms that can also reach difficult-to-access measuring points. The portfolio is complemented by enclosed high-precision linear encoders for grinding machines. Francesco Palumbo, Encoder Sales at Renishaw, says: “With our solution, we get the last micrometres of accuracy out of the process and ensure optimal grinding patterns.”

CBN tools for higher productivity

In addition to the machine and metrology, the tool remains a central factor for stable grinding processes. After several years of development, the Kapp Niles Group from Coburg has introduced new specified CBN roughing and finishing grinding wheels for rotor machining. The tools were developed for machining cast rotors and complement the company’s existing CBN line.

In the roughing process, a newly used grain is designed to reduce heat input through optimised coolant supply and larger chip spaces. In industrial applications, according to the company, the material removal rate Q‘w was multiplied and grinding time was reduced by up to 30 percent in combination with the lower heat input. This also makes it possible to machine high allowance situations economically, such as pre-cast rotors with a profile allowance of 2 to 4 millimetres. Pre-machining of the rotor profiles is no longer necessary; the milling process can be eliminated.

For finishing, an optimised CBN grain is used that is specifically designed for cast-iron machining. The aim is to increase tool life while maintaining consistently high component quality. The CBN grinding wheels can be used individually or combined as a performance package. Existing tools can be upgraded; the solutions have been proven in industrial use. “Customer feedback shows that we have struck a chord with the optimised CBN tools and can support our customers’ production in a needs-based and high-performance way,” says Andreas Paatz, Head of Service/Tools/Digitalisation.

Grindinghub 2026

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Supply reliability as part of stable processes

A holistic view of the grinding process also includes the reliable supply of suitable tool blanks and materials. Ceratizit, based in Luxembourg, presented itself at Grinding Hub with its “Rods & Preforms” business unit and its “Private Label” division, focusing on its portfolio for tool manufacturers.

“At Grinding Hub, in line with the motto ‘Reliability Redefined’, we are showing our fully integrated value chain: from powder to finished semi-finished product. Especially in times when availability is the top priority, we therefore ensure our customers the highest level of supply reliability combined with premium quality,” announces Michael Knittl, Head of Sales and PM at Ceratizit.

The developments on show include extensions to the ultrafine portfolio, for example for solid-carbide milling, as well as new milling blanks for micromachining with up to seven coolant channels. “This optimises milling performance thanks to targeted cooling in the engagement zone and increases tool life, of course with full stability of the shank and the finished ground tool,” Knittl adds. In addition, Ceratizit offers carbide substrates whose recycled tungsten carbide powder, according to the company, is reprocessed to 99 percent using advanced metallurgical technologies and 100 percent renewable energy. Michael Knittl adds: “And in this category, too, we are constantly working on new ways to expand the application range of these substrates!”

The examples show how grinding is evolving: away from an isolated machining step and towards integrated systems comprising machine, tool, metrology, process knowledge and reliable supply. Modern grinding processes are designed to reduce forces, lower thermal loads, secure quality directly in the machine and shorten machining times.

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