It must be lightweight – because the workpieces are primarily used in aerospace technology. Delicate yet highly durable components are created from solid metal blocks. 'We mainly machine aluminum and titanium for our customers,' says Volker Manz. The operations manager of AMAG components Karlsruhe GmbH relies on high-performance machines for milling the high-performance materials. 'It is immensely important for us that the machining centers are reliable, can be used flexibly, and of course, that they mill extremely precisely,' he summarizes the requirements. In recent years, the company has gained good experiences with several 5-axis machining centers from HERMLE, such as the C 30 U, C 40 U, and C 62 U. 'We needed additional manufacturing capacities for large workpieces up to 1,300 millimeters, so the second C 62, this time as a UP variant, was a given.'
Since 2022, the former Aircraft Philipp Karlsruhe GmbH has been 100% part of the Austrian AMAG Austria Metall AG as AMAG components. The corporate group thereby extends its value chain. Thanks to high recycling expertise, AMAG is able to process metal waste generated during component manufacturing at the German locations into high-quality rolled products at the Austrian plant in Ranshofen. This so-called closed loop not only saves valuable raw materials but also saves 95 percent energy compared to primary production.
Smart functions
In aerospace technology, every detail counts. Therefore, AMAG components leaves nothing to chance. 'First Time Right' is more than just a guiding principle here; it is a lived practice. Current example: The 5-axis machining center C 62 UP dynamic, which produces in the highest quality thanks to measuring probes and break control. 'Until now, we used the measuring system less actively on our other machines,' reports Volker Manz.
The wear-free, optoelectronic probe aligns the component virtually, even inaccurate clamping leads to perfect results. 'This allows us to achieve a very high process reliability, and the operator does not have to touch and reposition the component again,' describes Volker Manz a significant advantage. To fully exploit the machine's potential, AMAG components uses the pallet changer PW 3000, which is suitable for large and heavy loads up to 3,000 kilograms.
Full control
The PW 3000 is controlled with the intuitively operable management software HACS (HERMLE Automation-Control-System). Before an order starts, the intelligent software automatically takes over the most important checks: Are the zero points loaded? Is the pallet in the system? And of course – are all required tools available? If something is not right, it immediately informs the operator via real-time transmission.
Like all machines from AMAG components, the C 62 UP is also connected to the internal Factory Operations Monitoring. This allows employees to keep track of all machine statuses at any time and intervene quickly if necessary. 'We can manufacture 24/7, but usually, the weekend is free of work,' notes Volker Manz. 'We want to be an attractive employer for our workforce – automation supports us in this, of course.'
Closed material cycle
It takes several hours of runtime to machine a part – the C62 UP removes up to 90 percent of the original mass. The necessary flexibility is provided by 70 tools in the machine, which is supplemented by the additional magazine ZM 135 with 135 more. 'For example, when we mill the hinges from a metal block, the machine has to remove a lot of material,' explains CNC miller Jonathan Gabel. The chips are then washed, dried, and pressed into briquettes. 'This makes us part of the AMAG value chain,' says Volker Manz. This means concretely that the contract manufacturer in Karlsruhe obtains the material from the parent company, which then carefully processes the chips back at the headquarters.
Real precision work was the delivery of the new C 62 UP. 'Our hall doors are low – HERMLE had to partially disassemble the machine to even get it into the building,' recalls Volker Manz. 'It was a matter of millimeters to maneuver the system through. The delivery and installation by HERMLE went smoothly and exactly according to schedule.'
Flexible personnel deployment
The C 62 UP with connected pallet changer has been in operation since November 2024. Can a first conclusion be drawn? 'Thanks to the pallet handling, we are countering the shortage of skilled workers because we can plan and control the tasks and their distribution much better,' says Volker Manz happily. The workforce also appreciates the smart system. 'We asked who would like to take primary responsibility for the C 62 UP and received several applications right away. The machine is very popular.'
This is also confirmed by Michael Jakob, Head of Maintenance: 'We machine with four machines from HERMLE, one of which has been in operation for more than 20 years. The after-sales service is exemplary, and I am very satisfied with the performance and reliability of the systems.' In case of emergencies, HERMLE usually manages to ship spare parts on the same day the error is reported. 'Depending on the severity of the problem, we get the next available technician, which minimizes downtime.'
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