DOUBLE PROCESSING FOR
LARGE ALUMINUM STRUCTURAL PARTS
Big Casting Machine: WH 10000
WH 10000
WH 10000 – Parallel processing from two sides
The WH 10000 is a horizontal 5-axis machining center for large aluminum castings. Based on HELLER standard components and Wenzler kinematics, the WH 10000 is the ideal machining center for extremely large die-cast aluminum structural parts.
The design of the WH 10000 offers decisive advantages for the machining process of large aluminum structural components. Two linear 3-axis units face each other on one machine bed. The centered workpiece is located on a horizontal swivel axis (A-axis) and can be machined from both sides simultaneously in double-spindle mode in a single clamping operation. Each linear unit is equipped with a 5-axis milling head with two NC rotary axes per head.
Technical highlights of the WH 10000
- High agility
- 5-axis machining
- Two spindles in use
- Large traverse range
- Fast automatic tool change
- Minimum quantity lubrication (MQL)
- Clear view for the operator
- Central chip disposal
- Automatic loading and unloading by robot/gantry
WH 10000
Workpieces
Machining large aluminium castings places high demands on machines, tools and processes. With big-casting and giga-casting components, large workpieces must be machined precisely and cost-effectively, often whilst dealing with complex geometries. Modern solutions for machining big-casting components rely on high-performance machining centres, stable machine structures and optimised tooling concepts to remove material efficiently. In addition, the parallel machining of Giga-Casting components enables a significant increase in productivity, as several workpiece areas can be machined simultaneously. This reduces machining times and allows large aluminium structural components to be manufactured cost-effectively.
WH 10000
High-frequency spindle with tool interface
The WH 10000 machining center developed in-house combines two 5-axis machining units, each with the 4th and 5th axis in the tool. The two spindles ensure flexible machining from two sides. The high-frequency spindle installed in the milling head is equipped with an HSK63 tool interface and enables up to 16,000 rpm.
Swivel head with HSK-A 63 tool holder
- Maximum cutting performance thanks to a compact overall design and robustly dimensioned spindle bearing
- Thermal stability and precision thanks to continuous water cooling
- Sturdy, ribbed guide carriage with high dynamic rigidity and damping
- Small clearance for perfect penetration into the workpiece
- Horizontal spindle for optimum chip evacuation
Automatic tool change
The chain-type tool magazine offers 51 positions per machining unit. Tools are changed directly using a pick-up mechanism. The tool-changing area is located immediately adjacent to the machining area. Combined with the high axis dynamics, this ensures consistently short chip-to-chip times.
Quick tool change for short cycle times
- Each machining unit is equipped with a chain magazine featuring 51 magazine slots
- Tool lengths of up to 450 mm are possible
- Max. Ø without free adjacent space: 120 mm
- Max. tool weight: 8 kg; load capacity per magazine: 250 kg
WH 10000
State-of-the-art electronics
The WH 10000 is equipped with an integrated absolute measuring system on the X, Y and Z axes. The machining centre operates with digital drives and features a control cabinet with a cooling system. To improve energy efficiency, braking energy is also fed back into the mains at a synchronised frequency.
- Integrated absolute measuring system on the X, Y and Z axes
- Digitally controlled drives for precise motion sequences
- Control cabinet with integrated cooling system for temperature regulation
- Energy recovery: braking energy is fed back into the mains at a controlled frequency
- This improves the energy efficiency of the machining centre
Good scalability and integration
The workpiece can be loaded directly onto the machine table using a gantry loader or robot, and unloaded after machining. To boost productivity, several WH 10000 machines can be operated in series. Rely on Wenzler’s expertise for optimally coordinated production processes.
Good suitability for automation and integration
- Direct loading and unloading of the workpiece by robots from the front
- Direct loading and unloading from above possible for gantry automation
- Large roller door for ample access
- Optimal integration into automation systems thanks to a clear separation from the loading side
WH 10000
Optimal accessibility
The WH 10000 Big Casting machine offers excellent accessibility. One side of the machining centre serves as the loading side for automation. A large roller door opens the working area from the front and top. This allows robots, gantry systems or similar equipment to be used optimally for automation. To provide the operator with a clear view, provision has been made for connecting a handheld control unit for set-up tasks.
Optimal access to the machine from three sides is also ensured for servicing. The machine can be accessed from the side via doors, and there is sufficient space inside for maintenance work without the need to dismantle the machine.
Loading side
- Highly automatable using robots and gantry systems
- wide, motorised work area door designed as an NC axis
Operator side
- Maximum ease of use during set-up and production
- Main control unit in a console design for optimum ease of use
- Good visibility into the work area thanks to large safety screens
- Smooth-running work area door with linear guides opens the work area within the control zone
- LED lighting in the work area
- Large screen with multi-touch
- LED status light displaying processing progress
Maintenance areas
- Central media supply area on the side of the machine
- The media supply and process valves are located on the side of the machine
- The machine’s maintenance area is situated at the top, providing optimal access to the linear axes
WH 10000
Supply and disposal
You can’t make an omelette without breaking eggs. This is particularly true of the WH 10000 series machining centres: as extremely robust and reliable machines, they are designed for 24/7 production. To ensure your results remain consistently precise, we have an efficient solution for chip disposal wherever chips are produced.
Fluid supply, lubrication and chip removal
- Clearly laid-out fluid supply area with excellent accessibility for easy maintenance
- Centralised oil-air lubrication, as well as purge air and tool interface cleaning, for reliable machine operation
- Minimum quantity lubrication (MQL) directly through the spindle
- Fast and space-saving chip removal via free-fall chip discharge, central chip conveyor and stainless steel work area cladding
Control technology
The WH 10000 is equipped with integrated absolute measuring systems in the NC axes. The state-of-the-art Siemens SINUMERIK ONE control system ensures smooth operation and optimum usability of the machine. The machining centre operates with digital drives and features a water-cooled control cabinet. To improve energy efficiency and performance, braking energy is fed back into the grid at a synchronised frequency, for example.
Machine control
Siemens SINUMERIK ONE
- Ergonomic main control unit in a console design
- Optimally tailored to HELLER machining centres
- Digital drive technology and modern system architecture
- Fast real-time communication via Profinet
- IO-Link for sensor diagnostics and parameterisation
- SINUMERIK Operate user interface for efficient machine operation
WH 10000 – High agility for greater productivity
A great deal of know-how and experience is required when it comes to increasing agility and efficiency in the machining of large structural components. The outstanding properties of the WH 10000 offer particular advantages for industrial applications. Talk to us about individual and efficient processes for your requirements.
Double processing for
large aluminum structural parts
Big Casting Machine: WH 10000