WH 10000 for machining gigacastings is due to be delivered shortly

Foundry-Planet on Tour at Wenzler in Spaichingen. In conversation with the managing directors Wolfgang and Ingrid Wenzler, one key topic took centre stage: the optimisation 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 components. Wenzler therefore has technological access to the HELLER modular system and benefits from the HELLER Group’s global presence and service network.

Unlike many competitors, Wenzler sees itself not merely as a machine supplier, but as a partner that delves deeply into processes and examines the interplay between foundry, machining and OEM in detail.

This is particularly evident in the company’s commitment to viewing the value chain not in isolation, but always taking into account the steps both before and after machining. Consistent reference points and alignment within the manufacturing process are crucial to avoiding machining errors. Wenzler relies on close collaboration with tool manufacturers and suppliers, delves into the finer details of drilling and milling technology, and consistently uses minimum quantity lubrication (MQL) to ensure process stability and sustainability.

A key factor in the company’s success is the expertise and experience of its staff: Many processes are literally assessed ‘by ear’.

As the machines are designed to be extremely stable and possess excellent damping properties, process noises can be precisely identified and – based on 20 years’ experience with aluminium structural components – reliably verified. 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 ensure that lessons learnt from projects can be utilised in the long term – an area where large suppliers often fall short.

Wenzler also sees considerable potential in the interaction between foundry and machining. Although foundry operators frequently claim to be able to work with minimal allowance, practice shows that material properties and machinability vary greatly, even with identical alloys. Closer, early-stage collaboration could yield enormous efficiency gains here. Wenzler’s message is clear: the value chain must be understood holistically and coordinated across company boundaries.

Machining of giga and mega castings

When it comes to giga and mega casting projects, Wenzler is well positioned.

The company is integrated into the value chain via a leading European partner using the WH 10000 machine, underlining its role as a specialist in structural components and longitudinal beams. Wenzler’s machine designs are tailored to the specific requirements of large aluminium castings – from flexible logistics and parallel machining units to a thermally neutral construction. The key factor here is ‘gold standard’ availability: Machines must operate reliably 24/7, even under harsh production conditions.

During an informative tour with the management team, shortly before the delivery of the large machines, we had the opportunity to see for ourselves the technical capabilities as well as the logical requirements and solutions.

WH 10000 – parallel machining from two sides

The WH 10000 is a horizontal five-axis machining centre for machining large aluminium castings. Based on HELLER standard components and Wenzler kinematics, the WH 10000 is the ideal machining centre for extremely large die-cast aluminium structural components.

The design of the WH 10000 offers key advantages for the machining process of large aluminium structural components. Two three-axis linear units are positioned opposite each other on a machine bed. The centred workpiece is mounted on a horizontal swivel axis (A-axis) and can be machined simultaneously from both sides in a single clamping operation using dual-spindle operation. Each linear unit is equipped with a five-axis milling head featuring two NC rotary axes per head.

Technical highlights

Technical highlights of the WH 10000:

• High agility
• Five-axis machining
• Two spindles in operation
• Large travel range
• Fast automatic tool change
• Minimum quantity lubrication (MMS)
• Unobstructed view for the operator
• Centralised chip removal
• Automatic loading and unloading via 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

In the face of international competition, Wenzler believes the European industry must stand together more closely. Instead of thinking in terms of competing for margins and individual contracts, greater openness and cooperation are needed – particularly with regard to China, where projects are implemented uncompromisingly and free from economic constraints. “We’re all in the same boat. If the OEMs start to falter, it affects the entire supply chain,” is the urgent appeal.

Wenzler is thus positioning itself as a highly specialised 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 interplay across the entire value chain – from casting to final machining.

About August Wenzler Maschinenbau GmbH:

Wenzler is a mechanical engineering company based in Spaichingen, founded in 1954. The company develops and manufactures machining centres and production solutions, which are used in particular for 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. Through this affiliation, Wenzler combines its specialisation and experience with HELLER’s global presence and systems expertise, and benefits from its worldwide sales and service network. This strengthens Wenzler’s market position and enables access to new markets.