Schabmüller taps into MAPAL’ s expertise in aluminium
EDITOR’ S CHOICE FULL SERVICE SOLUTION
MAPAL
Schabmüller taps into MAPAL’ s expertise in aluminium
MAPAL has handled tool management at automotive supplier Schabmüller for some time. The Aalen-based tool manufacturer has now also taken over CAD / CAM programming for components, including simulations. With growing requirements for aluminium machining, the manufacturer values this fullservice solution.
Schabmüller Automobiltechnik GmbH( SMI) in Großmehring near Ingolstadt has been an automotive supplier since 1988 and has increasingly specialised in the efficient manufacture of large series. The parts are installed in vehicles made by Mercedes, Porsche, Audi, BMW and Jaguar, among others. SMI operates predominantly as a Tier 2 supplier. Major clients are Aludyne and Strojmetal, which directly supply the automotive industry as an aluminium foundry and forge.
Until a few years ago, Schabmüller produced cylinder head covers for the VW 3.0-litre V-group engine in quantities of up to 320,000 a year. The components, for which Schabmüller also handles installation, are still produced, but the volume has already decreased. However, other major orders have arrived, making the company less dependent on the combustion engine.
“ The production of suspension parts has begun since then. This gives us the opportunity to diversify ourselves in this direction”, says managing director Helmut Häckl.“ Our business has developed and pursued precisely this goal.” However, the new components pose challenges for Schabmüller, too.
Schabmüller manufactures hub carriers in pairs on a double spindle machine from SW. The image shows the use of disc milling cutters with indexable inserts from MAPAL.
When becoming involved in the production of suspension parts, Schabmüller had whole new experiences. Particularly for electric vehicle components, projects are sometimes postponed, originally planned quantities are not reached, or additional changes are required at short notice before series production begins. Häckl knows why:“ Up until the end, the OEMs gather experience in load tests for vehicles that are becoming increasingly heavier due to the weight of the batteries. This means that certain components are designed in a more stable way to cover all borderline situations.” Stephan Streck, technical consultant at MAPAL, explains using the example of a hub carrier. As issues with stiffness arose during driving. Almost at the last minute, another surface had to be machined and a stiffening rib was added.
Schabmüller has to plan the facilities and prices for the components before their exact design is known, which always presents the manufacturer with challenges.“ Cycle time is the decisive factor for getting an order”, says Häckl.
MAPAL involved from the outset
To get a better grip on these short-term changes and continue optimising overall production, Schabmüller decided to bring MAPAL on board already at the CAD / CAM programming phase.“ We have a very cooperative partnership with MAPAL and appreciate their rapid response times”, explains Häckl.“ So we felt good about expanding our cooperation to CNC programming and simulation.” MAPAL is already involved in tool design for new projects and in charge of tool management. These services are tailored to the client’ s needs. These include tool scheduling, pre-adjustment, dispensing and reconditioning, technical support for series production, tool and cycle time optimisations, and tool life optimisations.
22 PECM Issue 75