Please note: this text is a translation of the orginal press release. Please refer to the original file in German at the end of the page.
August Wenzler Maschinenbau, a HELLER company, and BENZ Tooling are joining forces to take the machining of megacasting components for e-mobility to a new level.
The transformation of the automotive industry calls for new manufacturing technologies. In the field of e-mobility, large-format aluminum structural components — known as “megacastings” — are becoming increasingly important. These complex components replace hundreds of individual parts, reduce weight, and drastically shorten assembly times. At the same time, they demand the highest standards in machining due to large machining volumes, long cycles, and the need for the highest precision.
August Wenzler Maschinenbau GmbH, based in Spaichingen, has taken on this challenge. With its WH 10000 series, the company offers a machine platform specifically designed for machining large aluminum castings. Combined with BENZ Tooling’s 5-axis heads, motor-spindles, and angle heads, the result is a solution that sets new standards in precision and productivity.
The WH 10000 horizontal 5-axis machining center is based on a robust dual-spindle design. Two linear 3-axis units are positioned opposite each other and machine a centrally clamped workpiece in parallel from two sides. This allows large megacasting components, such as front or rear subframes, to be fully machined in a single setup.
The workpiece is mounted on a horizontal swivel axis. The fourth and fifth axes are housed in the BENZ milling heads, ensuring maximum freedom of movement. Integrated motor spindles with speeds of up to 16,000 rpm (HSK-A63) ensure stable machining. Each unit features a magazine for 51 tools with a fast pick-up changer. The WH 10000 can be fully automated and utilizes efficient minimum-quantity lubrication as well as digital drives for low-maintenance operation.
The BENZ 5-axis head enables simultaneous control of all axes for hard-to-reach contours. Its rigid design and highly dynamic drives ensure precise positioning. Inside, position measurement systems track the positions of all relevant components, while IO-Link signal transmission provides status data such as temperature and speed for diagnostic purposes. The rotary distributor with slip ring technology guarantees reliable media and power transmission during rotation.
The integration of three core technologies from BENZ Tooling—the 5-axis head, motor-spindle, and angle head—creates a perfectly coordinated system unit. This technology partnership enables automakers to make the paradigm shift to megacasting highly productive and cost-effective.
Nadine Flassig
Marketing & Communication
+49 7803 504300-350
Nadine.Flassig@benztooling.com
BENZ GmbH Werkzeugsysteme
Kinzigpark 3
77723 Gengenbach, Germany
BENZ Tooling is one of the world's leading manufacturers and suppliers of components and systems for tool and machine tooling technology. The company employs about 300 people and is represented in over 30 countries worldwide.
