When a weightlifter loses grip on the barbell at a crucial moment, not only is the competition lost - there is also a significant risk of injury. Especially at peak performance, where maximum weights are used, a secure grip determines success, safety, and health. To ensure that the barbell reliably rests in the hand, the foundation for top performance begins not only in training but already in manufacturing. Here, every detail counts: Only when grip, handling, and haptics are perfectly coordinated can the athlete achieve their full potential - without the risk of the bar slipping.
As a market leader in knurling technology, Hommel+Keller is a sought-after expert in haptics. Their tool solutions are also in demand for the production of barbells. The company not only provides standard solutions but also develops customized tool concepts that are precisely tailored to the requirements of each application. This results in products that give athletes worldwide the crucial advantage in safety and performance.
For a leading American barbell manufacturer, a new design of a tangential tool holder from the QUICK brand was implemented in conjunction with special knurling rollers. Additionally, the customer requested to mark the products with text and to improve the areas between the grip surfaces visually through targeted diamond smoothing.
The challenges in this project are multifaceted: Materials with tensile strengths of 1400 to 1600 N/mm² are used, the raw material is usually not pre-turned, and at the same time, radial pressure must be avoided. Additionally, there are high demands on the stability of the tool holder while allowing for easy adjustment. The dimensions also pose special requirements, as long barbells are typically up to two meters long and have six to seven knurling areas, with individual profile widths of about 180 to 200 millimeters. In close collaboration with the customer and based on numerous test series, Hommel+Keller ultimately succeeded in developing a customized tool package that meets all requirements.
Sigmund Grimm, CEO of Hommel+Keller Precision Tools GmbH: 'In partnership with the customer, we overcame these hurdles through intensive development work and test series, for example, in heat treatment and with special tooth shapes. The result is the extremely stable special holder of our Quick Series F761 and optimized knurling rollers. All of this leads to a significant increase in service life while achieving a perfect knurling pattern.'
The development of the special holder of the QUICK Series F761 in combination with optimized knurling rollers is reflected not only in a significantly extended service life of the tools but also in an absolutely precise knurling pattern. Especially with the profile types, Hommel+Keller can ensure the highest flexibility and quality. Among other things, the profile RGE30° with divisions of 1.0 to 1.5 millimeters is used. It ensures an even and clearly defined knurling. Furthermore, the profile shape or profile depth can be adjusted variably.
For particularly grippy applications, fully formed, pointed pyramids are realized, while the so-called Volcano profile with small craters on the pyramid tips ensures a secure and ergonomic grip.
These profile types are complemented by precisely defined application data: workpiece diameters of 25, 28, 28.5, and 32 millimeters, cutting speeds of 180 to 200 revolutions per minute, and feeds of 0.2 to 0.3 millimeters in the X direction and 0.3 to 0.4 millimeters in the Z direction. Sigmund Grimm: 'With this combination of profile variety, process stability, and tool safety, Hommel+Keller offers barbell manufacturers worldwide customized solutions that set the highest standards in both mass production and elite sports.'
Knurling, smoothing, labeling: Everything on one machine
A central principle of Hommel+Keller is: 'Always everything on one lathe.' Instead of using several machines for different processing steps, the precision tool manufacturer provides complete solutions that ensure the highest efficiency and quality.
For processing the unknurled residual areas, it was proposed to use a zeus Diamond Smoothing Tool GW 520 directly during the turning process instead of separate centerless grinding. The result: a flawless surface in just one clamping. Sigmund Grimm: 'Our zeus diamond smoothing technology offers the highest level of process reliability. It can be seamlessly integrated into existing processing workflows without requiring additional work steps on other machines. This eliminates any additional setup and idle times.'
Furthermore, the possibility was created to customize barbells - for example, with logos or inscriptions. The marking is done with the zeus Precision Marking Tool MW432. The spring-loaded system is suitable for different workpiece diameters and allows for flat and longitudinal inscriptions up to the collar. This led to the idea of the Signature Series, where functionality and branding go hand in hand.
From the gym to the Olympics
Sigmund Grimm: 'Hommel+Keller now supplies a variety of barbell manufacturers worldwide - from producers of mass goods for home use and gyms to providers for elite sports. Names are not mentioned for competitive reasons, but one thing is clear: Those who set standards in the industry rely on precision tools from Aldingen.'
Whether mass-produced for dumbbells or world-class barbells - Hommel+Keller stands on the winner's podium together with the athletes. Because in the end, it is the final touch that matters: the precision of the knurling, the quality of the surface, the perfect handling. It is here that it becomes clear that a barbell is not just a barbell.
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