Albrecht Wüthrich Maschinen + Mechanik AG’s fleet of machines is designed for precision turning and milling workpieces. The company recently invested in a Swiss manufacturing solution from Fehlmann with an integrated Erowa automation concept to produce very small series of more complex precision workpieces using full automation.

From a start-up in a basement to a model company.
It started in 1971 in the Wüthrich family’s basement. Wüthrich Senior started a knife sharpening service out of the basement of his home. Compressors and repairs for machine parts were added later, when an increasing number of components had to be newly made. So Wüthrich invested in turning and milling machines, laying the foundation for the manufacturing company it is today. Investments were also made in training. Three apprentices are currently training as production mechanics and polymechanics. The company has been led since 2001 by Sara Wüthrich (owner, Finance Director) and Peter Birrer (Managing Director).

Outstanding machine fleet
With four CNC lathes and seven milling machines, the company focuses predominantly on smaller to medium-sized components, but with a Hedelius (3500 mm x 1000 mm path of travel) and Matec HV 30, also has the capability to produce larger workpieces. 

P. Birrer. “It’s important to us to always keep our machine fleet and team apace with the state of technology. This means that we regularly invest in new machines and technologies and we continue to educate ourselves accordingly as a team. This forms the basis for our ability to produce the highest quality workpieces in the required tolerances and surface qualities. A modern production environment paired with our expertise also helps to continually make production reliable and economical.”

VERSA 825 for highly complex small series production
This is precisely where the new Versa 825 from Fehlmann comes in. A 5-axis simultaneous machining center with fully automated Erowa pallet handling.

P. Birrer: “There were a number of reasons for expanding our machine fleet. First, our volume of orders for smaller batches with highly complex workpieces has gone up. Specifically, this meant expanding our production to include an independent manufacturing island capable of both serial production of single parts and unmanned small series production. To do this, the system should be designed for uncompromising high precision. Because there is a wide range of machine tools in this segment, we had to conduct an extensive evaluation, which definitely didn't make the decision any easier.”

P. Birrer: “The Versa as a technical solution is incredible. An important and crucial detail, for example, is that the CAM data is transferred directly to the control system from the post-processor - without extra work - and this works perfectly. The whole machine concept including automation won us over 100%. But the machine concept is only part of it. For such a complex solution, the service is also crucial. If the machine is at a standstill, we need to get help fast. Our experience with Fehlmann was absolutely outstanding right from the outset. They've reliably taken on the role of general contractor.”

Fehlmann as a general contractor
Jürg Solenthaler (Head of Sales CH, Fehlmann AG): “Acting as a general contractor is common practice for us. We’ve worked closely with Erowa for decades and develop the digital and mechanical interfaces of machinery for automation with Erowa specialists. As a result of these years of cooperation and experience, we’ve been able to develop complete solutions with Erowa that are designed to work perfectly together. This long-standing partnership, the sharing of knowledge and the mutual trust makes it much easier for us to act as a general contractor and take on responsibility.”

P. Birrer: “I can attest to that. Whenever something hasn't worked right away, the specialists from Fehlmann have always been able to provide us with professional support in every respect. It was exemplary. For background, I must also emphasize that this is our first time working with Fehlmann. Looking back, I have to say we’ve been very pleasantly surprised.”

“Outstanding overall concept”
From a technological standpoint, the Versa 825 with Erowa pallet automation has an exceptional design, according to P. Birrer: “Due to the complexity of the parts to be finished, we had to rely on a 5-axis simultaneous solution. The Versa, in my opinion, is one of the best machine concepts currently available on the market. Along with the purely chipping-related technological aspects, the machine's accessibility is excellently designed. Perhaps this is because Fehlmann originally started out in tool and mold making, where accessibility to the workpiece and running in was always of great importance. The developers had to brainstorm a few ideas for the machine concept. You especially appreciate this when you're standing at the machine setting up a new part. And because we machine many small series and single parts on our Fehlmann machine, this happens to us relatively often. “

New machine concept
J.Solenthaler: “Obviously it’s great to hear this sort of customer feedback. We designed the Versa machine concept completely from scratch ten years ago. The goal was to devise a manufacturing solution with the Versa model series that would provide perfect accessibility to the workpiece and be capable of incredible automation, all with the highest level of precision on the workpiece. Thanks to so much positive feedback from our customers, today I can say we've done it.”

To understand today's Versa machine concept, you need to know that the Fehlmann machine tools, as P. Birrer already mentioned, were originally designed for customers in tool and mold making industry, as well as as prototype builders. This means long running times with the highest level of precision and surface quality. Parts manufacturers were in the minority.

J.Solenthaler: “Our range of customers has changed over the last 20 years. Today, parts manufacturers make up the majority of our customers. This could be because the Versa concept speaks to the needs of this segment so well. At the same time, however, I must emphasize that we designed the Versa machine tools in terms of dynamics and productivity, including surface finish, in such a way that they are perfectly tailored for both tool and mold making, as well as series parts manufacturing. We were able to do this thanks to the powerful control technology from Heidenhain and our VERSA kinematic concept.

Fast and powerful:  18000 HSK-A63 spindle from Fehlmann
The Versa 825 is designed for 5-axis simultaneous machining of workpieces with a swing circle of up to 560 mm. The Fehlmann's own 18000 HSK-A63 spindle, with integrated Z-length compensation and a spindle power of 24kW at a maximum of 120Nm torque, brings adequate cutting performance for the range of parts to be cut by Wüthrich AG, with the required precision up to IT6 and corresponding perfect surface qualities, as standard in tool and mold making. For over 35 years, Fehlmann has relied on Heidenhain control systems and drives, in this case the TNC 640. Chip removal is also designed for unmanned manufacturing over the weekend.

The Fehlmann-Erowa automation concept
The Erowa-Leonardo automation concept saves a huge amount of space, only requiring an installation area of 2x2 meters. The max. number of pallets totals 32 UPC pallets (size 320/320 mm). The Leonardo automation can also be operated in combination with UPC and ITS 148 pallets upon customer request. The transfer weight is 80 kg (120 kg optional). Setup work can be done directly on the integrated loading station, without having to take the pallets out of the system.

Unmanned weekend production
The Leonardo system used at Wüthrich has 23 Erowa UPC pallets with clamping solutions tailored for the range of components. The Leonardo automation fits perfectly with the Versa machine concept. The Erowa automation has a specific interface for the Heidenhain control system, so that the pallets can be controlled via CNC pallet management.

P. Birrer: “If the order situation calls for it, we can utilize the machine unmanned during the weekend and on a third shift during the week. The production parameters should be specifically designed for unmanned production. Every company has their own approach here. We aim for safety when setting the cutting parameters. This means we don’t exhaust the tool’s cutting parameters to their full extent so we can prevent them from breaking or wearing out prematurely. We also have service life monitoring, which we determined based on experience and have recorded in the system. Finally, every time the tool is changed, it goes through tool control and is measured and inspectedby laser. The ideal placement for tool control is between the main spindle and tool storage, so that the tools can be measured in one go without going out of their way.”

Important: large tool storage
Keyword tool storage: For unmanned serial single production, as is the case here, tool storage plays an important part in keeping enough tools and replacement tools available.

J. Solenthaler: “When it comes to unmanned production, it’s crucial to invest in adequately large tool storage right at the start. If it turns out later that the tool storage isn’t big enough, it’s very expensive to retroactively integrate larger tool storage. Then when unmanned production can’t reach its full capacity due to the tool storage being too small, it’s very frustrating.”

Would invest in the same system again
When asked by SMM if he would invest in the same system again in hindsight, or if he would do things differently, P. Birrer said, “The manufacturing solution is an ideal fit for our workpiece and batch size segment. It runs better than I had hoped. Overall, Fehlmann devised a manufacturing island that is technologically perfect. The process reliability and repeatability are outstanding. Moreover, Fehlmann has a point of contact who knows the technology well and speaks the same language we do. If I had to decide all over again today, I would do exactly the same thing.”

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