Schabmüller stopped programming itself back in 2018.“ For CAD / CAM, we need specialists who know this subject matter inside out”, says Häckl.“ If we only tackle two to four new projects a year, a staff member can’ t be fit here.” Schabmüller has used the machine manufacturer’ s services for programming from time to time since then. However, there was no option for 3D simulations, which meant the manufacturer knew that not all options for optimising cycle times were being used.
Now that MAPAL is involved from the beginning, this has changed. NC programming, simulation and tool management are now perfectly intertwined. For instance, simulation data is included in tool planning, which helps detect potential collisions at an early stage. It is possible to respond immediately to component changes by the OEMs before the start of production. Modifications are made in the 3D simulations before the tools are finished. Streck explains the importance of simulation:“ If you don’ t catch adverse changes in good time, costs can run into the five figures.”
Production at Schabmüller mainly takes place on multi-spindle machines. Hub carriers are machined by SW on a double spindle.
Simulation also plays a key role in optimising machining. For instance, it shows approach angles that can be used to improve material removal. Data from the computer can also be used to reduce tool wrapping.“ This type of detail is much easier to detect in simulations than looking through the window into the machine”, says Streck.
Forged parts, not cast aluminium
The suspension parts involve a shift in starting material from die cast aluminium to forged aluminium. Forged parts have much higher load indicators than cast parts. The higher stability is required in particular for electromobility. However, this also increases machining requirements to achieve the desired cycle time. Material removal and thus the volume to be machined are much higher here, which requires adapted milling strategies.
The material properties have also changed, as Stephan Streck explains:
In the warehouse system, MAPAL provides all tools needed for a component via the tool management. For hub carriers, 45 to 55 different tools are required.
All of MAPAL’ s aluminium machining expertise is required to find solutions here.
“ Compared to aluminium cast parts, the forged material has a much lower silicon content. This means that the chip doesn’ t break well, long chips are produced in machining, and we need to deal with smeared blades. All of MAPAL’ s aluminium machining expertise is required to find solutions here.” Schabmüller currently uses forged aluminium to produce some of the hub carriers, steering knuckles and control arms made in Großmehring.
High-volume milling cutter NeoMill- Alu-QBig used before its market launch
Another aspect of improving processes is MAPAL bringing new tools on board as soon as they are available and promise benefits. As application engineer Eugen Bien notes, the new indexable insert milling cutter NeoMill-Alu-QBig was used at Schabmüller before it even officially came on the market.
This new indexable insert milling cutter from MAPAL stands out for its top performance in high-volume aluminium milling. It is designed for use at speeds up to 35,000 min-1 to achieve the maximum possible material removal rate. For a tight fit despite high centrifugal forces, screws with increased tensile strength are used to hold
Issue 75 PECM 23