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User Short Report #1

More productive with process reliability

Machined trestle, key component for door locking systems from Feldmann Türsysteme in Velbert. In focus: The rough machining of step drilling of different sizes and the application of chamfers.

Multi-stage customized countersinking tools guarantee process reliability and significantly increase the productivity by reducing tool change times and almost tripling tool life.

In local transport alone, 4.8 billion passengers traveled by bus in Germany in 2022. Passenger safety is, of course, the top priority. High safety standards are already defined during the production of buses and cover various aspects.

Feldmann Türsysteme GmbH in Velbert, which has been developing and manufacturing components and assemblies for door systems, drives and locking systems for automatic doors for cars, commercial vehicles and machines since 1941, is also subject to the strictest safety standards and precision requirements. An absolutely safe manufacturing process was therefore also required for the central manufacturing product made from EN-GJMW-400-5, the trestle used in automatic door drives.

Automation and safety

Hans-Georg Nondorf, Area Sales Manager Avantec in NRW (left) and Robert Weinheimer, Production Manager FTS (right)

A shortage of skilled workers and enormous cost pressure were the main reasons why Feldmann fully automated the production process some time ago and now manufactures in series on two DMG machines that are linked via pallet automation. The previous process had to be changed in order to manufacture the cast parts more productively and reliably.

Feldmann recognized the need for optimal tool solutions, especially for low-manpower series production from castings, because casting misalignment and shrinkage cavity are always a challenge for the process stability of the tools, especially in automated production. And this is a task for Avantec.

Innovative solutions for machining

Robert Weinheimer, Production Manager and responsible for prototype construction at Feldmann for 10 years, and Hans-Georg Nondorf, Area Sales Manager at Avantec, agreed that “a high degree of accuracy is required here” and that the process can only become safer and more effective, if each part runs automatically 24/7.

Avantec developed three customer-specific multi-stage countersinking tools, of which each roughs a drill and simultaneously machines a chamfer. The smallest tool with a diameter of 29.8 mm, which is used for the middle drill, was particularly surprising because it only has one cutting edge. Weinheimer was a little skeptical at first, but Avantec has proven otherwise.

All three tools have been in stable use for over a year. Switching from conventional single tools to the custom-made combination tools from Avantec reduced the tool change times and made the overall process significantly more productive and, above all, safer. Tool life has almost tripled, while precision and safety in series production are guaranteed 24/7.

Automated production process on two DMG machines, linked via pallet automation. Series: 6000 parts/year. Challenge: Creating process reliability and increasing productivity.

Individually developed multi-stage countersinking tools for precise casting machining ensure a reliable process.

The overall process is significantly more productive, in conjunction with combined roughing and chamfering, a high chip volume and the reduced tool change times.

Future outlook

The successful partnership between Feldmann Türsysteme and Avantec Zerspantechnik shows how innovative solutions in the manufacturing industry can be realized through close cooperation between customers and suppliers.

“I had never thought that the tools would work so reliably. However, Avantec has convinced us of the opposite – all three tools are stable in use, the process is safe and more productive.”

Statement Robert Weinheimer, Production Manager FTS

Tool Tech

Workpiece: trestle
Material: Malleable cast iron EN-GJMW-400-5
Batch size 6000 parts/year
Machining: Roughing and chamfering of stepped drills Ø 20/29.8, 33/39.8 and 44/51.8 mm
Tools: Xtra series – multi-stage countersinking tools individually developed and manufactured
Cutting data on request

Shortcut

User: Feldmann Türsysteme GmbH | Velbert
Sector: Mechanical Engineering | Hydraulics | Pneumatics
Process: Casting machining | trestles | Roughing and chamfering of stepped drills
Focus: Optimize machining time, make automated process reliable
Solution: Individual multi-stage countersinking tools
Result: Process reliability | tool life tripled | productivity significantly increased