It seems that the ingot mold casters of the CSA Herzogenburg GmbH have a heart made of aluminium. About 6,500 t of this light material is processed each year in the low pressure and gravity permanent mold casting facility of the casting experts in Lower Austria. The emphasis is on chassis components and large components for commercial vehicles. A view into the production quickly reveals: CSA has specialized in sophisticated castings. “The complexity of the parts is not only due to the often complicated geometry of the parts. Particularly large castings are a challenge, especially when one works with multiple casts, like we do”, explains Markus Kieberger, the managing director of CSA.

The high complexity of the components also has implications on subsequent processes, such as the post-machining of the parts. “Originally, an outsourcing was in discussion for the post-machining of large castings”, the managing director explains. “Then, however, we have decided to manage this work step in our company, in order to have under control the entire value-added process and also to be able to keep the logistics tight.”

So, in February 2014, the first Heckert HEC 630 Athletic has been purchased. The essential decision criteria in favor for the horizontal machining centre were the large working area and the high stability. At a clamping surface of 800 mm × 630 mm, the HEC 630 Athletic allows an interference diameter of 1,250 mm (maximum length up to 1,550 mm) and a maximum workpiece height of 1,250 mm. “Heckert could prevail also because of the possibility to adapt the machine exactly to our demands. For example, column modifications have been made for a better machining of large parts with high process reliability”, says a pleased Mr. Kieberger. The NC rotary table can carry a workpiece weight of up to 1,500 kg. The rotational speed of 70 rpm can be optionally increased to up to 500 rpm and thus, it can even be used for turning operations. The traverse paths of (X/Y/Z) 1,200 mm × 950 mm × 1,200 mm offer sufficient space for the machining of large parts. The spindle with its rotational speed of up to 15,000 rpm transmits the drive power of 82 kW without a gearbox via a HSK-A 100 tool interface. The tool magazine offers 80 storage spaces with a maximum tool length of 800 mm. The tools may have a weight of up to 35 kg. In January 2015, another HEC 630 Athletic was purchased. This one is, except for an adapted spindle, identical in construction to the first machine. “Our main aim has been a capacity expansion”, Kieberger explains. “With the first machine, we perform 19 weekly shifts with almost always the same parts. On one hand, the new sister machine allows us to increase the throughput for this part, on the other hand it also allows to additionally produce other parts in alternating operation”. The machines are arranged in a machining cell shifted by 90° to one another and can be loaded and unloaded from the same workplace with crane support.