Zimmermann Delivers Its First "FZU37" Portal Milling Machine to Die Casting Manufacturer in Michigan Turbo for Production

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At Century Tool, a "FZU37" portal milling machine is providing a breath of fresh air in production. Zimmermann Inc., the US subsidiary of F. Zimmermann GmbH, has designed this machine specifically to meet the requirements of tool and mold making for large-format die-cast components. Thanks to modern CNC control, a spacious work area and high-performance machining, Century Tool has increased its productivity by up to 30 percent with the new Zimmermann.

How can the immense number of hours required for finishing and roughing very large workpieces be reduced? This question was addressed by Century Tool, a tool and die manufacturer based in Fenton, Michigan. The company is part of the Tooling Tech Group (TTG), a leading manufacturer of tools in the United States.

In order to significantly increase productivity, a smaller machine that was no longer in use was to be replaced by a new portal milling machine, thereby expanding the extensive machine park. Century Tool approached Zimmermann Inc. in Wixom, Michigan, with this requirement. Cornelius Kiesel, Managing Director of Zimmermann Inc: "We knew which machine was best suited to the customer and designed the specifications accordingly."

More Travel on the Same Surface Area

Zimmermann supplied a CNC portal milling machine from the "FZU37" series with an installation space of 16.4 × 13.1 × 4.9 feet. With the same space requirement, the hogger has 79 percent more travel compared to the previous machine. It is suitable for machining aluminum and composite materials. Because it does not require a fixed machine foundation, it can be set up flexibly on solid industrial floors—the existing foundation could continue to be used thanks to specific adaptations. The machine table is firmly connected to the "FZU37". This means that the workpiece does not have to be moved during machining. The machine is equipped with a tool changer, cover, mist extraction system, high-pressure coolant supply, tool laser and a measuring probe. The HSK 63 and HSK 80 tool holders are used.

Cornelius Kiesel: "We integrated an extended spindle housing for deeper cavities and increased the side walls. We also reinforced the machine table so that we could also machine complex shapes." Thanks to intensive preparation and close coordination with the customer, commissioning went quickly and smoothly. Zimmermann project manager Alfio Campagna supervised the installation on site.

Process Reliability Thanks to Modern Software

The portal milling machine is equipped with the TNC7, the latest control generation from Heidenhain. Among other things, this offers the possibility of graphically measuring any workpieces up to complex free-form parts in the shortest possible time using new probing cycles. This allows the TNC7 to visualize the entire production environment: clamping devices, workpiece and machine room. This data can be used in advance during programming for a realistic 3D simulation of the machining process. CAD software from VISI and a CAM solution from Tebis are used. Operator David Hawes is particularly impressed by the smart programming: "I draw contours using the touchscreen and the program automatically converts them into plain text." The connection of the existing programs with the new control system also works perfectly and makes start-up and operation smooth. User-friendly screen layouts and a customizable touchpad further enhance ergonomics.

The CNC control also offers the option of component monitoring. This protects the spindle bearing from overload, for example. At the same time, it detects increased component wear in the drive train during operation. This function provides valuable data for preventive maintenance and the evaluation of the machine's process capability. This is an important feature for Century Tool, as the paver only produces very large molds on the Zimmermann machine—and often removes more than 90 percent of the material over several days. The "FZU37" is one of the first machine tools in the USA with a TNC7 control system. The employees received several days of training directly from Heidenhain.

Impressive Variety of Applications

Tom Bradford is Production Manager at Century Tool and operates the "FZU37": "On the new Zimmermann machine, we mainly machine components made of P20 steel, which is the industry standard for casting molds. We also use various aluminum materials." Century Tool manufactures a variety of large tools for compression molding composite materials and other substrates for a wide range of industries, from automotive to heavy-duty, from off-highway to agriculture, and from motorsports to infrastructure such as water tanks. "We specialize in Class A body parts, where the highest surface quality and tight tolerances are required," describes Bradford. "With the Zimmermann machine, we consistently achieve excellent results—even with large mold structures." The "FZU37" is currently working in two-shift operation. Often also in lights-out mode: the operation runs fully automatically without an operator being present—or an employee controls and monitors the system remotely.

On Course for Expansion

Bradford: "As a tool supplier, we supply Tier 1 suppliers and OEMs in the manufacturing sector. We have built up a good reputation in the automotive and heavy-duty sectors. We want to use this expertise to expand into other industries such as aerospace and consumer goods. Our core competence in composite molding gives us a real advantage. With the 'FZU37', we achieve excellent RA surfaces with consistent quality, even with much larger structures." Thanks to the table size and the fast and precise machining, Century Tool has already been able to increase its productivity by up to 30 percent.

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