Foundry-Planet on Tour at Wenzler in Spaichingen. In conversation with Managing Directors Wolfgang Wenzler and Ingrid Wenzler, one central topic took center stage: the optimization of the entire value chain in machining technology.
Wenzler has been part of the HELLER Group since 2009 and, as such, is responsible for the machining of aluminium structural parts. Wenzler therefore has access to the HELLER modular system and benefits from the global presence of the HELLER Group and its service network.
Unlike many of its competitors, Wenzler sees itself not only as a machine supplier but also as a partner that delves deep into the processes and considers the interaction between foundry, machining, and OEMs in detail.
This is particularly evident in the company's approach of not viewing the value chain in isolation but always considering the steps before and after machining. Consistent references and alignments in the manufacturing process are crucial to avoid machining errors. Wenzler relies on close cooperation with tool manufacturers and suppliers, goes into the details of drilling and milling technology, and consistently works with minimum quantity lubrication (MQL) to ensure process stability and sustainability.
An important factor for success is the experience and knowledge of the employees: many processes are literally assessed ‘by ear.’
Since the machines are extremely stable in design and have excellent damping properties, process noises can be precisely identified and reliably verified based on 20 years of experience with aluminium structural parts. The insights gained are then incorporated into the adjustment of process parameters, tool designs, and clamping strategies.
Wenzler is therefore committed to systematic knowledge management in order to make empirical values from projects permanently usable – a weak point that is often lacking in large suppliers.
Wenzler also sees considerable potential in the interaction between foundry and machining. Although foundry operators often claim to be able to work with minimal allowances, practice shows that material properties and machinability vary greatly, even with identical alloys. Closer, early cooperation could bring enormous efficiency gains here. Wenzler's appeal is clear: the value chain must be understood holistically and coordinated across company boundaries.
Processing of Giga and Megacastings
Wenzler is well positioned with regard to giga and megacasting projects.
The company is integrated with a leading European partner along the value chain with the WH 10000 machine, underscoring its role as a specialist for structural parts and side members. Wenzler's machine concepts are designed to meet the special requirements of large aluminium cast components – from flexible logistics and parallel machining units to thermally neutral construction. The decisive factor here is availability, which is worth its weight in gold: machines must run reliably 24/7, even under harsh production conditions.
During an informative tour with the management shortly before the delivery of the large machines, we had the opportunity to see for ourselves the technical skills as well as the logical requirements and solutions.
Big Casting Machine WH 10000 – Parallel Machining from Two Sides
The WH 10000 is a horizontal 5-axis machining center for large aluminium casting machining. Based on HELLER standard components and Wenzler kinematics, the WH 10000 is the ideal machining center for extremely large die-cast aluminum structural parts.
The design of the WH 10000 offers decisive advantages for the machining process of large aluminum structural components. Two linear 3-axis units face each other on a machine bed. The centered workpiece is located on a horizontal swivel axis (A-axis) and can be machined from both sides simultaneously in double spindle operation in a single clamping. Each linear unit is equipped with a 5-axis milling head with two NC rotary axes per head.
Technical highlights of the WH 10000:
- high agility
- 5-axis machining
- two spindles in use
- large travel range
- fast automatic tool change
- minimum quantity lubrication (MQL)
- unobstructed view for the operator
- central chip disposal
- automatic loading and unloading by robot/gantry.
Details here:
https://august-wenzler.de/de/wh10000.html
https://www.heller.biz/de/maschinen-und-loesungen/big-casting-bearbeitungszentrum-wh-10000
Appeal to European Car Manufacturers
Wenzler believes that European industry needs to stick together more closely in the face of international competition. Instead of competing for margins and individual orders, more openness and cooperation are needed – especially with regard to China, where projects are implemented uncompromisingly and free from economic constraints. “We are all in the same boat. If the OEMs falter, it affects the entire supply chain,” is the urgent appeal.
Wenzler thus positions itself as a highly specialized solution provider that focuses not on size but on process expertise, close customer integration, and sustainable availability. The Spaichingen-based company is convinced that the key to competitiveness lies in the interaction of the entire value chain – from casting to final machining.
About August Wenzler Maschinenbau GmbH:
Wenzler is a mechanical engineering company based in Spaichingen, Germany, founded in 1954. The company develops and manufactures machining centers and production solutions that are used in particular in the machining of light metal and structural components for the automotive and supplier industries.
Since 2012, Wenzler has been majority-owned by the HELLER Group, a leading international manufacturer of machine tools. This affiliation allows Wenzler to combine its specialization and experience with HELLER's global presence and system expertise, benefiting from its worldwide sales and service network. This strengthens Wenzler's market position and enables access to new markets.
