Automated Tool Manufacturing for Solid Forging
With around 6,000 employees, the Hirschvogel Group is a leading automobile supplier in the area of solid forging of steel and aluminum as well as further finishing processes. With locations in Germany, Poland, China, India, the USA and Mexico, the company group serves all major markets.
Their headquarters in Denklingen – the company was founded here in 1938 – is also the headquarters of Hirschvogel Umformtechnik GmbH. Countless components are produced here using hot, cold, or warm forging. Around 200 skilled workers manufacture the necessary molds on site in the tool shop. Automated monoBLOCK machining centers from DMG MORI ensure flexible and efficient manufacturing of the complex components. The latest installation is a DMU 85 H monoBLOCK with PH Cell 2000.
Increased components for electromobility
In cooperation with automobile manufacturers, Hirschvogel got involved early on in product development and the production of prototypes. Consequently, the company has had an active role in the transformation of the market. At the same time, Hirschvogel has continued to reliably serve the traditional market. Ralph Schramme comments: “This has meant we have had to continuously optimize our processes to meet increasing capacities and the high demands on flexibility.” The limited toolmaking production space requires highly efficient manufacturing solutions. “We can continue to increase our capacities for the long term with 5-axis machining centers and automation solutions from DMG MORI.”
Testing automation solutions for international use
Hirschvogel has already been using a rotary pallet storage system on monoBLOCK and duoBLOCK machines as well as a DMU 65 monoBLOCK with a PH 150 for a long time. “We often replace two machines by using this kind of manufacturing solution,” says Ralph Schramme. “Lightly manned production through the night or on the weekend also provides us with additional scope for production.” The central toolmaking facility is also responsible for testing manufacturing solutions for use at other sites. “We have now also installed the DMU 65 monoBLOCK with PH 150 at sites in India, Mexico and Poland.”
DMU 85 H monoBLOCK: Reliable manufacturing thanks to horizontal machining
The latest installation for toolmaking by Hirschvogel is a DMU 85 H monoBLOCK with PH Cell 2000. The horizontal spindle of the machining center offers two decisive benefits, Matthias Lenggeler, foreman in the area of toolmaking milling, says explaining the acquisition: “On the one hand, the vertical chip fall ensures high process reliability and, on the other, the vertical travel path is considerably larger.” The versatility of the machine is ideal for the diverse range of parts used in toolmaking. “We mainly machine individual parts or very small series,” Matthias Lenggeler says describing their daily business. The automation solution needs to be just as flexible. The PH Cell 2000 was designed by DMG MORI with just this flexibility in mind. The modular storage system offers up to 21 pallet spaces, depending on the size of the pallet. Hirschvogel uses pallet sizes of 630 × 630 mm, which enables 17 spaces. A further advantage according to Matthias Lenggeler: “The positioning of the pallets on three levels ensures a compact footprint.” The PH Cell 2000 only needs a footprint of 16.5 m².
Easy operation thanks to CELOS with Pallet Master
A further feature of the PH Cell series is the simple commissioning within just a few days, thanks to a defined interface and the modular construction kit. The CELOS-APP Pallet Master takes care of the control system directly via the machine control or the optional additional control panel. The PH Cell 2000 is designed for machining larger components. It can handle a transfer weight of up to 2,000 kg. “This gives us the option of not only machining smaller molds, but also larger mold components,” adds Matthias Lenggeler. “Depending on requirements, we can alternatively load a pallet with clamping devices for several components.”
Counteracting the shortage of skilled workers with automation and new technologies
“Automated manufacturing solutions are our standard as they allow us to optimally utilize our production space,” emphasizes Ralph Schramme. They also provide a sensible means of counteracting the shortage of skilled workers at home and abroad. “We will also look into new technologies, for example, additive manufacturing.” It is only possible to continuously improve your processes by investments in innovation.
Hirschvogel Holding GmbH
Dr.-Manfred-Hirschvogel-Straße 6
86920 Denklingen, Germany
www.hirschvogel.com