Partnership with Benz GmbH Werkzeugsysteme
Machine and tool working in perfect harmony for 5-axis megacasting machining
BENZ Tooling and Wenzler are combining their expertise in a high-performance 5-axis system solution for the precise and cost-effective machining of mega and gigacastings in the e-mobility sector.
Parallel processing for maximum productivity
The WH 10000 is designed as a horizontal 5-axis machining centre and combines the proven design principles of HELLER’s standard components with the specially developed Wenzler kinematics. This system is specifically engineered to deliver high agility, rigidity and process stability.
When combined with BENZ Tooling’s high-performance 5-axis heads – including motorised spindles and angle heads – the result is a comprehensive solution that sets new standards in precision, dynamics and productivity. The machine and tool are perfectly matched, enabling stable processes even at the highest cutting rates.
Precision and dynamism for the machining of large castings in the future
The automotive industry’s transition to e-mobility is presenting new challenges for manufacturing. Large-format aluminium structural components – known as mega- or gigacastings – are, in particular, rapidly gaining in importance. Their complexity, size and functional integration call for high-performance machine designs, high-precision tools and maximum process reliability.
August Wenzler Maschinenbau GmbH meets these requirements by focusing squarely on innovative machining solutions – and does so by working closely with BENZ Tooling in a spirit of partnership.
Three BENZ areas of expertise in a single system solution
What makes this project unique is the seamless integration of three core technologies from BENZ Tooling. The 5-axis head, motor spindle and angle head form a precisely coordinated system unit. The result is harmonised kinematics with high rigidity and maximum process reliability – ideal for the precise and cost-effective machining of megacasting components.
The demands of megacasting are high: large machining volumes, long cycle times and, at the same time, the highest precision. BENZ Tooling’s 5-axis technology is specifically designed to meet these challenges. It offers high power reserves in a compact design and is optimally matched to the Wenzler machine – ensuring stable, high-precision processes with maximum flexibility.
Cooperation with Mapal Dr. Kress KG
Bundled competence for the machining of aluminium structural components: Cooperation with Mapal Dr. Kress KG
Under great time pressure, a project that was demanding in many respects was realized together with the tool manufacturer from Aalen. The decisive factors here were flexibility, process know-how and the special properties of the Wenzler VKM.
Cooperation with Mapal Dr. Kress KG
Mapal Dr. Kress KG, based in Aalen, East Württemberg, has a high level of process and product expertise in cutting tools. Precision, long tool life and above all process reliability are required here. Versatile high-performance tools and special tool holders are among the company’s strengths.
Concentrated expertise
Together with a team from Mapal, August Wenzler Maschinenbau GmbH was able to successfully implement the requirements of a sports car manufacturer. Among other things, Mapal’s experience in the PCD sector was decisive in this.
The chassis subframe is a typical component in the automotive sector that functions as a rear axle beam in vehicles. The Wenzler VKM, which enables optimum automated loading and unloading, is ideally suited for machining. The working area, which is easily accessible from two opposite sides, ensures a safe spatial separation of the robot from the human workers. In addition, the unique machine design allows the finishing of such components in one clamping.
Thanks to the bundled expertise, the cycle time for machining the aluminium structural component was successfully reduced to 16 minutes. Wolfgang Wenzler, Managing Director of August Wenzler Maschinenbau GmbH, summarizes the advantages of the cooperation as follows: "It was noticeable that our two companies have a lot of experience in this area and that everything can be decided quickly".
Partnership with Heller
Flexible machining with Wire and Arc Additive Manufacturing:
cooperation with Heller Maschinenbau
Solution developed jointly with Heller
As part of our partnership with Gebr. Heller Maschinenfabrik GmbH, we have developed an additive manufacturing solution that can be integrated into our Wenzler VKM and VPM machining centers.
Economical process for prototypes and variant-rich small batches
In many cases, rapid production of prototypes and variant-rich small series is required, which previously could not be represented in a series process. Wire and Arc Additive-Manufacturing (WAAM) refers to an additive manufacturing technology that allows the workpieces to be machined completely in a single setup in the hybrid machining center, saving time and costs.
Hybrid machining of complex metal components
With the help of WAAM technology, we can realize three-dimensional buildup welding and machining in a hybrid machining center. Complex metal components are generated generatively by alternately depositing and removing material. In this way, the corresponding workpieces can be supplemented, modified and repaired. Keyword Industry 4.0: in keeping with the times, quality assurance is based on the recording and control of the collected process data.
The process at a glance using the battery frame as an example
When machining a battery frame for e-mobility, the WAAM process starts with joining the bar profiles by an integrated CMT welding process in the machining center. Then the extremities with any geometry, such as lugs and cylinders, are applied using an additive process. Now the weld seams can be leveled, and contours or functional surfaces can be machined in the same setup. In the next step, the desired surface quality can be produced by milling, brushing or grinding, depending on individual requirements. Holes and threads relevant for assembly can now be introduced. The process quality has also been confirmed by tensile tests and micrographs in cooperation with well-known OEMs.
Cooperation with Honsel
More effectiveness through integrated coil assembly in the machining center: cooperation with Honsel Umformtechnik
Intermediate steps such as workpiece transport or workpiece clamping concepts are often neglected when planning machining processes. Our new machining concept ensures increased effectiveness of the overall system.
Partnership with Honsel Umformtechnik
In cooperation with the company Honsel Umformtechnik GmbH in Fröndenberg/Ruhr, we have developed and tested a new machining concept. The concept of integrated coil assembly in the machining center ensures that the predicted overall equipment effectiveness (OEE) is achieved.
Increasing real overall equipment effectiveness
Machining and assembly with automatic feeding in the machining center ensures faster, more cost-effective machining with fewer N.I.O. parts and thus increased effectiveness of the overall plant. In highly interlinked plants, the availability of each individual participant plays a very important role. However, attention must also be paid to the interfaces between the process steps, because these often form the bottleneck between the respective highly available plants. Only well-coordinated processes can achieve the previously predicted overall plant effectiveness.
Integrated machining and assembly of threaded inserts
Until now, wire thread inserts have been inserted after machining (drilling and thread forming) in the machining center by a separate handling system with setting devices. The position of the hole, the initial angle of the thread and many other factors have a considerable influence on process-reliable assembly. Therefore, we have also integrated coil assembly into the machining center. This allows the workpiece to be machined and assembled in a single clamping operation. Thus, tool parameters can influence assembly directly from the CNC machining.
Partnership with Römheld
Innovative condition detection increases process reliability: a new concept in cooperation with Römheld
For highly efficient machining of workpieces, the first priority is to optimise the cutting equipment. There are a large number of influencing variables – but the initial situation is largely determined by the workpiece blank.
Partnership with Römheld
Based on this idea, August Wenzler Maschinenbau GmbH has developed an innovative clamping concept in close cooperation with Römheld GmbH Friedrichshütte in Laubach, Hesse, Germany. It enables the measurement of various component states in the process. From loading to machining to unloading, the quality can be constantly monitored and seamlessly documented. The core of this innovation consists of the new clamping devices, the electrification as well as the digital data transmission from the clamping device. Römheld supplies the appropriate clamping technology for this, August Wenzler implements it and evaluates the data. We are very much looking forward to further successful cooperation in this field.
Focus on workpiece blank quality
It is crucial to monitor the quality of the blank and correct clamping. In this way, it is decided at an early stage whether further machining is possible and whether further machining is worthwhile. If a component is detected as defective, valuable resources can be saved: then the workpiece is rejected at an early stage and does not go through the entire process chain.
