CERATIZIT, GROB, OPEN MIND and TELKO have realized a joint demonstration project at the CERATIZIT Technical Center in which CAD/CAM, cutting tools, machine technology and metalworking fluids come together. The result is not only an impressive example of five-axis machining, but also a symbol of what becomes possible when knowledge, technology and craftsmanship are perfectly aligned like in a “beehive.” The project will be presented from 10 to 13 March at the TELKO stand during the TechniShow.
The choice of a honeybee is no coincidence. The insect symbolizes collaboration and dedication: values that also form the core of the Technical Center and the manufacturing industry. Tinus Zuetenhorst, Managing Director of CERATIZIT Netherlands, explains:
“The concept behind our Technical Center has always been to realize projects with partners that inspire customers and bring knowledge together. Project Beehive perfectly illustrates how collaboration between specialists leads to results that would not be achievable individually. With a complex workpiece like this, collaboration is literally the key.”
Design and digital preparation
The design of the honeybee has an interesting background. Kain Borst of OPEN MIND worked intermittently on the 3D model over a period of five years.
“It started as a personal project, but the technical complexity made realization difficult,” Borst explains. “Thanks to the collaboration with CERATIZIT, GROB and TELKO we were finally able to bring the design to life.”
The digital preparation was carried out in hyperMILL, where machining strategies were simulated and optimized. Fragile elements such as the antennae, legs and wings required smart strategies to maintain structural stiffness for as long as possible. Only after sufficient supporting material had been removed were the finer machining operations performed. Programming focused on achieving optimal tool load, which limited heat input and prevented vibration.
The five-axis interpolation of the GROB G350 ensures smooth transitions and constant cutting conditions. For the thin elements the focus was on minimizing tool pressure to prevent deformation. Ball-nose end mills with a small stepover were used for the curved surfaces to achieve a uniform surface finish. By varying the milling paths, the bee’s body obtained a subtle, natural texture: a perfect balance between engineering and aesthetics.
72 hours of craftsmanship and precision
Manufacturing the honeybee required approximately 72 hours of machining time. The original aluminium block weighed 32 kg, while the finished part weighs only 6 kg. This ratio clearly illustrates the level of precision involved. The finest details, such as legs and antennae with diameters of only 3 to 5 mm, required specialized machining strategies, fixturing methods and tool selections.
For this project, GROB provided a five-axis G350 machining center at the Technical Center. Iggy Rolando of GROB explains that he was immediately enthusiastic about the vision behind the project.
“This project is about knowledge sharing and collaboration. The G350 is ideal for this type of work because the machine combines maximum precision with high dynamics. The aluminium honeybee is a perfect example of that.”
The machine played a key role in the process. Thanks to the rotary swivel table and the horizontal spindle, the workpiece can be optimally positioned, allowing the tool to reach even the most difficult areas. Michael Falk of CERATIZIT adds:
“The kinematics of the GROB G350 allow us to select approach angles that reduce the required tool length while improving coolant supply and chip evacuation. That is crucial when machining delicate structures such as the legs and antennae of the honeybee.”
Aluminium milling at the highest level
Machining aluminium required a carefully selected combination of tools and metalworking fluids. CERATIZIT supplied eighteen different milling cutters with 28 tool positions, each designed with optimized cutting geometries and controlled chip evacuation to ensure maximum process reliability, minimal heat input and excellent surface quality.
The tools used, including ball-nose end mills with small radii and light-cutting CCR cutters, feature substrates, geometries and coatings specifically developed for aluminium machining. Although aluminium is generally considered easy to machine, it is susceptible to chip adhesion and built-up edge formation. To prevent this, the chip flutes are extremely smoothly polished and coated with a non-stick coating. Aluminium milling cutters also have fewer flutes than steel cutters, further improving chip evacuation.
The liquid tool
TELKO, formerly Optimol Lubrication and a Castrol distributor since 1958, supplied the metalworking fluid, which they aptly describe as a “liquid tool.” Leon Verschuren of TELKO explains:
“In a machining process there are only two factors that come into direct contact with the workpiece: the cutting tool and the metalworking fluid. The right emulsion is therefore crucial for process stability, dimensional accuracy and surface quality. That is why we refer to our emulsions as liquid tools. They play a decisive role in determining the quality of both the process and the final product.”
Metalworking fluids such as Castrol Hysol SL 50 XBB, used in this project, play a key role in the machining process: they provide lubrication, reduce friction heat and effectively remove chips. This is particularly important when machining aluminium because the material expands more than steel. Efficient heat dissipation prevents dimensional deviations, improves surface quality and extends both tool life and process stability.
The GROB G350 machine itself was also equipped with high-quality Castrol lubricants that contribute to a stable and reliable production process. The use of Castrol MAGNA SW D 68 slideway oil ensures optimal guidance and wear protection, while Castrol Hyspin AWH-M 46 hydraulic oil guarantees stable operation of the hydraulic system, even under high loads and temperatures.
